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Repair Manual
Jetta 1999
Jetta Wagon 1999
Golf 1998
Engine Mechanical
Engine ID
AWD AWW AWP
Edition 07.2007
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Service Department. Technical Information
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
20 - Fuel Supply
21 - Turbocharger, Supercharger
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright 2012 Volkswagen AG, Wolfsburg
D3E80022B06
Jetta 1999 , Jetta Wagon 1999 , Golf 1998

Engine
. Volkswagen A - Edition 07.2007
AGMechanical
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Contents
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General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Engine and Transmission Mounts, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine, Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
2
2.1
2.2
3
3.1
3.2
3.3
4
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1
1.1
2
2.1
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00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
4
5
5
5
7
7
11
12
15
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block Crankshaft Bearing Shells Identification, from approximately 05.00 . . . . . .
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing Flange and Flywheel/Drive Plate Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and Connecting Rod Overview, Engine Code AWD . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and Connecting Rod Overview, Engine Codes AWW and AWP . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston and Cylinder Dimensions, Engine Code AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston and Cylinder Dimensions, Engine Codes AWP and AWW . . . . . . . . . . . . . . . . . . . .
Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Code AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Codes AWW and AWP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Seal, Ribbed Belt Side, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing Flange, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AG.
1
1.1
1.2
1.3
2
2.1
2.2
2.3
2.4
2.5
2.6
3
3.1
3.2
3.3
3.4
4
4.1
4.2
5
5.1
5.2
5.3
5.4
6
17
17
17
18
19
19
21
23
24
26
28
30
30
30
31
31
32
32
34
36
36
37
39
41
43
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1
1.1
1.2
2
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
45
45
45
46

Engine Mechanical - Edition 07.2007
2.1
2.2
2.3
3
3.1
4
4.1
4.2
4.3
4.4
5
5.1
5.2
5.3
5.4
5.5
5.6
6
Cylinder Head Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valvetrain Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seats, Refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Valve Lifters, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft, Checking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Guide, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Gear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Position Sensor Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
48
51
54
54
55
55
56
57
59
60
60
64
67
69
71
75
77
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . .. V. o.lk.s.w.ag. e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Fastener Tightening
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Diagnosis
and Testing . . . . . . . . . . . . . . .ar.an. t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ise
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Oil
ut Pressure and Oil Pressure Switch, Checking or a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
2
2.1
2.2
3
3.1
4
4.1
5
5.1
6
79
79
79
80
80
82
84
84
85
85
87
87
89
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Cooling System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Components Overview, Body Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Components Overview, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After-Run Coolant Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1
1.2
2
2.1
2.2
2.3
3
3.1
4
4.1
5
5.1
5.2
5.3
6
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19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
91
91
91
96
96
99
100
102
102
103
103
104
104
104
105
107
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20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
ii
Contents

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crash Fuel Shut-Off Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Power Control System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Diagnosis, Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank and Attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Engine Power Control Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . .
Meaning of Electronic Power Control Warning Lamp in Instrument Cluster . . . . . . . . . . . .
EVAP System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP System Routing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . n. A. G
. ..V.o.lk.sw
. a. g.e.n.A.G. . . . . . . . . . . . . . . . . . .
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Fastener Tightening Specifications . . . . . V. o.lk.sw
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Diagnosis and Testing . . . . . . . . . . .ris.e.d . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . .
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Fuel Pump, Checking . . . . . . . . .au. t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.a . . . . . .
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Accelerator Pedal Position Sensor
and Accelerator Pedal Position Sensor 2, Checking . .
Evaporative Emission Canister Purge Regulator Valve, Checking . . . . . . . . . . . . . . . . . .
EVAP System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Detection Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP System, Checking with Tester KLI 9210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
109
110
110
110
111
111
112
113
113
116
116
117
118
119
120
120
121
121
126
129
131
134
136
143
143
144
144
146
rrectness of i
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1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
2.3
2.4
2.5
2.6
3
3.1
4
4.1
4.2
4.3
4.4
4.5
4.6
5
5.1
5.2
5.3
6
21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Air System with Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger with Attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Air Cooler Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Turbocharger System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Turbocharger System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boost Pressure Regulation, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wastegate Bypass Regulator Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Air Pressure Sensor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger Recirculation Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boost Pressure Regulator Valve Vacuum Diaphragm, Checking . . . . . . . . . . . . . . . . . . . .
Deceleration Shut-Off Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
do
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1
1.1
1.2
1.3
2
2.1
2.2
2.3
2.4
3
3.1
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
5
149
149
149
150
151
151
155
157
158
160
160
161
161
163
163
165
166
166
167
169
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Contents
iii

1.1
2
2.1
2.2
3
3.1
4
4.1
4.2
4.3
4.4
5
Secondary Air Injection System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Air Injection System Components Assembly Overview . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three Way Catalytic Converter, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combination Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Air Injection Pump Motor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Air Injection Solenoid Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents
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170
171
171
174
176
176
177
177
179
179
180
182

00
General, Technical Data
General Information
1.1 Engine Number, page 1
1.1
Engine Number
The engine number (engine code and serial number) are lo

cated at the front of the engine/transmission joint.
The engine number consists of up to nine characters (alphanu
meric). The first part (maximum 3 letters) represents the engine
code, the second (six digit) is the serial number. If more than
999,999 engines with the same engine code are produced, the
first of the six characters is replaced with a letter.
The engine code is also included on the vehicle data plate.
In addition, a sticker with the engine code and serial number

AG. Volkswagen AG d
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The engine code -arrow- is also stamped on the engine lifting eye.
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1. General Information
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Specifications
2.1 Engine Data, page 2
2.1
Engine Data
Engine code
AWD
AWW
AWP
Manufactured
from 11.99
from 07.00
from 06.01
Displacement
ltr.
1.8
1.8
1.8
Output
kW at 1/rpm
110 at 5700
110 at 5700
132 at 5500
Torque
Nm at RPM 210 at 1750 to 4600 220 at 1950 to 4500 235 at 1950 to 5000
Bore
diameter mm
81.0
81.0
81.0
Stroke
mm
86.4
86.4
86.4
Compression ratio
9.5
9.3
9.5
RON
95 unleaded
95 unleaded
98 unleaded
System designation
Motronic ME7.1
Motronic ME7.1
Motronic ME7.1
Emission values in accordance with
TLEV 1
LEV 2
LEV 2
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TLEV = Transitional Low Emission Vehicles (emission val

ues Max. 0.125 g/mi HC)
LEV = Low Emission Vehicles (emission values max. 0.075
g/mi HC)
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Rep. Gr.00 - General, Technical Data
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2 knock sensors
2 knock sensors
2 knock sensors
OBD II
OBD II
OBD II
2 sensors
2 sensors
2 sensors
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Knock sensor control

On Board Diagnostic (OBD)
Oxygen sensor regulation
Catalytic converter
Exhaust Gas Recirculation (EGR)
Variable intake manifold
Variable valve timing
Turbocharger
Electronic Power Control (EPC)
Boost pressure regulation
Secondary Air Injection (AIR) system

10
Engine Assembly
General Information
1.1 Engine and Transmission Mounts, Aligning, page 3

1.2 Air Conditioning, page 4
1.1
Engine and Transmission Mounts,

Aligning
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Before loosening bolts, secure assembly
ut using the engine sup
ra
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port bridge -10-222 A- .
s
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-b- = minimum 10.0 mm
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-a- = 14.0 mm
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Engine Mount
Both bolt heads -1- must be flush with the edge -c-.
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Transmission Mount
The edges -a and b- must be parallel to each other.

1.2
Air Conditioning
Caution
The Air Conditioning (A/C) refrigerant circuit must not be

opened.
Note
The refrigerant circuit must only be opened in workshops with
trained personnel and the necessary range of tools and work

shop equipment.
To prevent damage to the A/C condenser and also to the re
frigerant lines/hoses, ensure that the lines and hoses are not
stretched, kinked or bent.
To facilitate removal and installation of the engine without having

to open the refrigerant circuit:
Remove the retaining clamp(s) from the refrigerant lines.
Remove the ribbed belt. Refer to
5.1 Ribbed Belt, page 36 .
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Remove the A/C compressor. Refer to Heating, Ventilation

and Air Conditioning; Rep. Gr. 87 ; Description and Operation .
Secure the A/C compressor to the tow hook so that the refrig
erant lines/hoses are not under tension.
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Note
Shield the bumper from damage using adhesive tape.
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Rep. Gr.10 - Engine Assembly
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Specifications
2.1 Engine Mount Tightening Specifications, page 5

2.2 Fastener Tightening Specifications, page 5
2.1
Engine Mount Tightening Specifications
Engine Mount
1-
Mount to body 1
23-
Bracket to body
Mount to engine mount bracket
40 Nm + an addition
al 90 (1/4) turn
25 Nm
100 Nm
Transmission Mount
1-
Mount to body 1
23-
Mount to body
Mount to transmission mount
bracket
Pendulum support to subframe 1
2.2
20 Nm + an addition
al 90 (1/4) turn
Always replace
Fastener Tightening Specifications
Components
Nm
M6
M7
M8
M10
M12
10
15
25
40
60
45
80
Bolts and Nuts
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M12
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Deviation from
Engine to transmission bolts
Engine to transmission bolts
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3-
Pendulum support to transmission 40 Nm + an addition

1
al 90 (1/4) turn
AG.
2-
Pendulum support to transmission 40 Nm + an addition

1
al 90 (1/4) turn
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Pendulum
40 Nm + an addition
al 90 (1/4) turn
25 Nm
100 Nm
2. Specifications
Prote
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by

Components
Converter to drive plate
Drive axle to drive flange/transmission
Bolt Size
Nm
60
40
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Removal and Installation
3.1 Engine, Removal, page 7

3.2 Engine, Securing to Assembly Stand, page 11
3.3 Engine, Installing, page 12
3.1
Engine, Removal
Special tools and workshop equipment required

Holding Fixture -VW 313-. Volkswage
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Engine and yTransmission
Holder -VW 540t gu
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-2024 Aor
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Shop Crane -V.A.G 1202- or Shop Crane -VAS 6100-
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Retainer
-3180-
Drip Tray -V.A.G 1306- or Drip Tray for VAS 6100 -VAS 6208-
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Torque Wrench -V.A.G 1331 Torque Wrench -V.A.G 1332 Engine-/Gearbox Jack -V.A.G 1383 A Engine Mount -T10012 Spring Type Clip Pliers -VAS 5024 A Step Ladder -VAS 5085-
Grease -G 000 100- (vehicles with a manual transmission)

(Part numbers are for reference only. Always check with your
Parts Department for the latest part number information).
M10 x 25, 8.8 Bolt
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Cable Tie
First, check whether a coded radio is installed. If necessary,

obtain the anti-theft code.
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The engine is removed downward together with transmission.

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Disconnect the battery Ground (GND) cable with the ignition

turned off.
AG.
All cable ties which are opened or cut off when removing the
engine, must be replaced in the same position when installing
the engine.
Remove the engine cover.
3. Removal and Installation
Squeeze the buttons together on the hose connections to remove

the connecting hoses.
Disconnect the connector -1- from the AIR pump.
Remove the air filter. Refer to Fuel Injection and Ignition;
Rep. Gr. 24 ; Description and Operation .
Disconnect the vacuum and vent hoses from the engine.
WARNING
The fuel supply line is under pressure! Wear protective goggles

and protective clothing to prevent injuries and contact with skin.
Before removing from hose connection wrap a cloth around the
connection. Then release pressure by carefully pulling the
hose off the connection.
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Remove the connecting hoses -arrows- between the Secon

dary Air Injection (AIR) pump/combination valve and the AIR
pump/air filter.
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Jetta 1999
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Engine

AG.
Disconnect the supply line -1- (with a white mark) and the sre
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turn line -2- (with a blue mark) and catch any leaking fuel
by
ed
a cloth.
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Disconnect the hose from the solenoid valve.ss au
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Squeeze the buttons together on the hose connection.

Seal the lines so that the fuel system is not contaminated by
dirt, etc.
Remove the intake hose between the mass airflow sensor G70- and exhaust turbocharger. Refer to Fuel Injection and
Ignition; Rep. Gr. 24 ; Description and Operation .
Loosen the intake hose (between the charge air cooler and the
throttle valve control module -J338- ) and remove it.
with a Manual Transmission
Disconnect the selector mechanism from the transmission.

Refer to Manual Transmission; Rep. Gr. 34 ; Removal and
Installation .
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The clutch pedal must not be pressed.
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Remove the slave cylinder for the hydraulic clutch. Refer to

Manual Transmission; Rep. Gr. 30 ; Description and Opera
tion .
with a Automatic Transmission

Disconnect the selector lever cable from the transmission. Re
fer to Automatic Transmission; Rep. Gr. 37 ; Removal and
Installation .
Continuation for All
Remove the sound insulation tray. Refer to Body Exterior;
Drain the coolant. Refer to
1.2 Cooling System, Draining and Filling, page 91 .
Remove the coolant hoses from the engine.
Note
spring type clip pliers -VAS 5024 A- or hose clip pliers -V.A.G
1921- are recommended for installing spring clamps.

Remove the pendulum support bolts -arrows- and support.
Disconnect and lay aside all electrical harnesses for the trans
mission, generator, and starter.
Remove the front exhaust pipe. Refer to
AG. Volkswagen AG d
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2.1 Exhaust System Components Overview, page l171
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Remove the power steering pump from the bracket and place
it to the side, the hoses remain connected. Refer to Sus
pension, Wheels, Steering; Rep. Gr. 48 ; Removal and In
stallation
Disconnect all electrical connections as necessary from the
engine and lay aside.
Remove the right and left drive axles from the transmission.
Refer to Suspension, Wheels, Steering; Rep. Gr. 40 ; Re
moval and Installation .
with Air Conditioning (A/C)
Remove the A/C compressor:
Observe the additional information and removal work. Refer

to 1.2 Air Conditioning, page 4 .
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fo
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Install the engine/trans. support -T10012- to the cylinder block

with a nut and a M10 x 25/ 8.8 bolt and tighten to approximately
40 Nm.
Note
Use the step ladder -VAS 5085- to remove the bolts.
10
AG.
Remove the engine mount to engine mount bracket bolts

-arrows-.
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Gently lift the engine and transmission using the engine-/gear

box jack -V.A.G 1383 A- .
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Remove the securing clamps for the powers steering pressure

line.

Remove the transmission mount to transmission mount brack
et bolts -arrows-.
Carefully lower the engine with transmission.
Note
Carefully guide the engine with transmission, when lowering, to

prevent damage to the bodywork.
3.2
Engine, Securing to Assembly Stand
Secure the engine to the holding fixture -VW 313- using the hold
ing fixture -VW 540- when performing repair work.
Procedure
Remove the transmission.
After separating the engine from the transmission, secure the
torque converter to prevent it from falling out.
Engage the engine sling -2024 A- with the retainer -3180- as
follows and raise using the shop crane -V.A.G 1202- from the
engine-/gearbox jack -V.A.G 1383 A- .
Belt pulley side: 3rd hole of rail in position 1.
Caution
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Use securing pins at hooks and pins.
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Flywheel side: 2nd hole of rail in position 5.
The peg positions on the carrying strap marked with 1 to 4 face
the belt pulley.
The bores in the hole rail are counted from the hook.
Secure the engine using the holding fixture -VW 540- to hold
ing fixture -VW 313- .
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3.3
Engine, Installing
Installation is in the reverse of removal, note the following:

Caution
When doing any repair work, especially in the engine compart

ment, pay attention to the following due to clearance issues:
Route lines of all types (for example, fuel, hydraulic, Evap
orative Emission (EVAP), coolant, refrigerant, brake fluid
and vacuum) and electrical wiring so that the original path
is followed.
To prevent damages to the lines, make sure there is suf
ficient clearance to all moving or hot components.
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Make sure the alignment sleeves for the engine to transmis

sion are installed in the cylinder block. Install if necessary.

Engage the intermediate plate at the sealing flange and slide
it onto the alignment sleeves -arrows-.
with a Manual Transmission
If necessary, check the centering of the clutch disc.
Check the clutch release bearing for wear and replace if nec
essary.
Lightly grease the clutch release bearing, the guide sleeve for
the release bearing and the input shaft splines with grease for
clutch plate splines -G 000 100- . (Part numbers are for refer
ence only. Always check with your Parts Department for the
latest part number information).
Install the hydraulic clutch slave cylinder. Refer to Manual
Transmission; Rep. Gr. 30 ; Description and Operation .
Install the shift mechanism. Refer to Manual Transmission;
Rep. Gr. 34 ; Removal and Installation, Servicing . Volkswa
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If necessary, adjust the selector lever cable.
olksRefer to Man
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d
ual Transmission; Rep. Gr. 34 ; General
Information .
se
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Install the selector lever cable to the transmission, adjust if

necessary. Refer to Automatic Transmission; Rep. Gr. 37 ;
Removal and Installation .
Adapt the automatic transmission control module 1.
When installing, ensure clearance to the drive axles.

Align the engine and transmission mounts. Refer to
1.1 Engine and Transmission Mounts, Aligning, page 3 .
Install the drive axles. Refer to Suspension, Wheels, Steer
ing; Rep. Gr. 40 ; Removal and Installation .
Install the front exhaust pipe. Refer to
2.1 Exhaust System Components Overview, page 171 .
Install the power steering pump. Refer to Suspension,

Wheels, Steering; Rep. Gr. 48 ; Removal and Installation .
AG.
Install the ribbed belt. Refer to

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Electrical connections and routing. Refer to Wiring dia

grams, Troubleshooting & Component locations.
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Install the intake hose (between the charge air cooler and the
throttle valve control module) and secure it.
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Secure the torque converter to the drive plate, only use new
nuts.
Install the connecting hoses between the Secondary Air In

jection (AIR) pump/combination valve and AIR pump/air filter.
Install the sound insulation tray. Refer to Body Exterior;
Fill with coolant. Refer to
Perform the Procedure after Voltage Supply Open Circuit.
Refer to Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis
and Testing .
13

Tightening Specifications
Bolted connections
Tightening
specifications
Bolts, nuts
M6
10 Nm
M7
15 Nm
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60
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45 Nm
80 Nm
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Deviation from
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Connecting bolts, engine to transmis M10
sion
Connecting bolts, engine to transmis M12
sion
Converter to drive plate
Drive axle to drive flange/transmis
sion
60 Nm
40 Nm
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Tightening torques of the engine/transmission mounts. Refer to

2.1 Engine Mount Tightening Specifications, page 5 .

Special Tools
Holding Fixture -VW 313-
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Holding Fixture -VW 540-
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Engine Sling -2024 A Retainer -3180-
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Shop Crane -V.A.G 1202or Shop Crane -VAS 6100 Drip Tray -V.A.G 1306- or
Drip Tray for VAS 6100 VAS 6208-
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4. Special Tools
15
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Torque Wrench -V.A.G
1331-
Engine-/Gearbox Jack V.A.G 1383 Aun

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Step Ladder -VAS 5085-
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Spring Type Clip Pliers VAS 5024 A-
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Engine/Trans. Support T10012-
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Torque Wrench -V.A.G

1332-

13
Crankshaft, Cylinder Block
General Information
1.1 Engine, page 17

1.2 Crankshaft, page 17
1.3 Cylinder Block Crankshaft Bearing Shells Identification,
from approximately 05.00, page 18
1.1
Engine
Note
Secure the engine to the assembly stand using the holding
fixture -VW 540- and spacers -VW 540/1B- when performing

repair work.
If large quantities of metal particles or abraded material are
detected during engine repairs, it may be an indication for a

damaged crankshaft or rod bearings. To prevent further dam. Volkswag
en AG
does
age, perform the following steps after the repair: swagen AG
Carefully clean the oil passages
Replace the oil filter
Crankshaft
Note
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spec
atio
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wit
1.2
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Replace the oil cooler
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Replace the oil injection jets
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Before removing the crankshaft, prepare for appropriate stor
age, so that sensor wheel does not make contact or become

damaged.
Secure engine to assembly stand using the holding fixture -
VW 540- and spacers -VW 540/1B- when performing repair

work.
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1.3
Cylinder Block Crankshaft Bearing

Shells Identification, from approximately
05.00
Cylinder Block Crankshaft Bearing Shells Identification

From the factory, the upper bearing shells are allocated to the
cylinder block with the correct thickness. Colored dots serve to
identify the bearing thicknesses.
Note
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the
cylinder
s
The arrow points in the direction of travel.
Color identification
S
R
G
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a
t
i
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wit
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s
Letter on cylinder
block
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The letters marked on the lower sealing surface of

block identify which bearing thickness must be installed in which
location.
Color of bearing
=
=
=
Black
Red
Yellow
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Rep. Gr.13 - Crankshaft, Cylinder Block
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The crankshaft bearing shells in the bearing caps are only

available as a replacement part with a yellow colored dot.
Description and Operation
2.1 Belt Drive Overview, page 19

2.2 Cylinder Block and Components, page 21
2.3 Crankshaft Overview, page 23
2.4 Sealing Flange and Flywheel/Drive Plate Overview, page

24
2.5 Pistons and Connecting Rod Overview, Engine Code
AWD, page 26
2.6 Pistons and Connecting Rod Overview, Engine Codes
AWW and AWP, page 28
2.1
Belt Drive Overview
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2 - Ribbed Belt Tensioner

To release tension on
the ribbed belt, pivot us
ing a open-end wrench.
Refer to
5.1 Ribbed Belt,
page 36
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1 - Bolt
25 Nm
rrectness of i
t to the co
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spec
atio
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es, in part or in w
l purpos
hole
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3 - Upper Toothed Belt Cover

4 - Center Toothed Belt Cover
5 - Bolt
27 Nm
6 - Idler Roller
7 - Tensioning Roller
Toothed belt, removing,
installing and tension
ing. Refer to
5.1 Toothed Belt,
page 60 .
8 - Toothed Belt
Mark the rotation direc
tion before removing.
Check for wear.
Do not kink.
Removing, installing
and tensioning. Refer to
5.1 Toothed Belt,
page 60 .
9 - Coolant Pump
Check for ease of move
ment.
If damaged or leaking replace completely.
Removing and installing, refer to 5.2 Coolant Pump, page 104 .
10 - O-ring
Always replace.
11 - Bolt
15 Nm
2. Description and Operation
19

12 - Toothed Belt Tensioner
Toothed belt, removing, installing and tensioning. Refer to 5.1 Toothed Belt, page 60 .
13 - Crankshaft Toothed Belt Gear
14 - Bolt
15 Nm
15 - Bolt
20 Nm
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90
(1/4)
turn.
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17 - Lower Toothed Belt Cover

18 - Bolt
10 Nm
Install using liquid locking fluid -D 000 600 A2- .
19 - Pulley
For the power steering pump.
20 - Bolt
25 Nm
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22 - Bolt
25 Nm
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21 - Ribbed Belt
Mark the rotation direction before removing.
Check for wear.
Do not kink.
Removing and installing, refer to 5.1 Ribbed Belt, page 36 .
rrectne
s
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16 - Bolt
90 Nm + an
Always replace.
Use the counter support -3415- to loosen and tighten.
Threads and shoulder must be free of oil and grease.
23 - Vibration Damper
Only possible to install in one position - Bores are offset.
Note the position when installing the toothed belt. Refer to 5.1 Toothed Belt, page 60 .
AG.
20

2.2
Cylinder Block and Components
1 - Knock Sensor 1 -G612 - Bolt

20 Nm
The tightening specifi
cation affects the func
tion of the knock sensor.
3 - Knock Sensor 2 -G66-
7 - Coolant Line
8 - Bolt
20 Nm
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6 - O-ring
Always replace.
rrectness of i
t to the co
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m
spec
atio
h re
n in
wit
5 - Inlet Spout
For the oil dipstick.
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4 - Oil Dipstick
The oil level must not be
above the MAX. mark!
Marks, refer to
Fig. Marks on the Oil
Dipstick , page 82 .
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10 - Bolt
15 Nm + an additional
90 (1/4) turn.
Always replace.
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9 - Oil Filter Bracket

Overview, refer to
2.2 Oil Filter Housing
Overview, page 82 .
11 - Oil Cooler
Coat the contact area to
the oil filter bracket, outside the seal, with sealing paste -AMV 188 100 02- . (Part numbers are for
reference only. Always check with your Parts Department for the latest part number information).
Ensure sufficient clearance to surrounding components
See the note in 1.1 Engine, page 17 .
12 - Nut
25 Nm
13 - Oil Filter Element
Remove using a tension strap.
Tighten by hand.
Observe the installation instructions for the oil filter.
14 - Gasket
Always replace.
15 - Bolt
10 Nm
21

16 - Engine Speed Sensor -G2817 - Connecting Piece
19 - O-ring
Always replace.
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18 - Bolt
15 Nm
21 - Bolt
45 Nm
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t to the co
nform
spec
at
i
h re
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in t
his
20 - Coolant Thermostat
Removing and installing, refer to 5.3 Coolant Thermostat, page 105 .
Note the installed position, refer to 5.3 Coolant Thermostat, page 105 .
Checking: Heat up the thermostat in water.
Opening begins approximately 86 C (187 F).
Opening lift, a MIN. of 7 mm.
22 - Accessory Bracket
For the generator, Air Conditioning (A/C) compressor, and power steering pump.
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23 - Engine Mount Bracket

Crankshaft Overview
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4 - Bearing Shells 1, 2, 3, 4 and

5
For the bearing caps
without oil grooves.
For the cylinder block
with a oil groove.
Do not interchange
used bearings (mark
them).
Vehicles from approxi
mately 05.00: Classifi
cation for replacement
part ordering, refer to
Fig. Cylinder Block
Crankshaft Bearing
Shells Identification ,
page 18 .
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5 - Bolt
65 Nm + an additional 90 (1/4) turn.
Always replace.
Fully threaded.
When measuring crankshaft radial play, tighten to 65 Nm.
rrectne
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t to the co
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spec
atio
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3 - Chain Sprocket
For the oil pump drive.
Check for wear.
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2 - Bolt
15 Nm
un
le
1 - Oil Pump with Chain

Sprocket
With a pressure relief
valve, 12 bar.
Before installing, check
to be sure both align
ment sleeves are
present (for centering oil
pump/cylinder block).
Removing and instal
ling, refer to
1.2 Lubrication Sys
tem, page 79 .
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2.3
AG.
6 - Bearing Cap
Bearing cap 1: Belt pulley side
Retaining tabs on the bearing shells and cylinder block/bearing caps must align above one another.
7 - Bearing Shell 3
See -item 4 Do not interchange used bearings (mark them).
8 - Sensor Wheel
Always replace.
For the engine speed sensor.
Only possible to install in one position - Bores are offset.
9 - Screw
23

Always replace.
10 - Thrust Washer
For bearing 3.
Observe the locating point.
11 - Crankshaft
Axial play:
New: 0.07 to 0.23 mm
Wear limit: 0.30 mm
Check the radial clearance using Plastigage:
0.01 to 0.04 mm
Wear limit: 0.15 mm
Do not rotate the crankshaft when measuring the radial play.
Crankshaft dimensions, refer to 3.2 Crankshaft Dimensions, page 30 .
Sealing Flange and Flywheel/Drive

AG. Volkswagen AG d
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Plate Overview
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Servicing the clutch. Refer to Manual Transmission; Rep. Gr.

30 ; Description and Operation .
24
or
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Note
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2.4

1 - Bolt
90 Nm + an additional
90 (1/4) turn.
Always replace.
Use the counter support
-3415- to loosen and
tighten.
Threads and shoulder
must be free of oil and
grease.
2 - Crankshaft Toothed Belt
Sprocket
olkswagen AG
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5 - Sealing Flange
Must be located on the
alignment sleeves.
Clean the sealing sur
face before installing.
Install using silicone
sealant -D 176 404
A2- .
Removing and instal
ling, refer to
5.3 Sealing Flange,
Belt Pulley Side,
page 39 .
To remove and install,
remove the oil pan.
6 - Cylinder Block
Crankshaft overview, refer to 2.3 Crankshaft Overview, page 23 .
Piston and connecting rod overview, refer to one of the following:
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4 - Seal
Replacing, refer to
5.2 Crankshaft Seal,
Ribbed Belt Side, Re
placing, page 37 .
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2.5 Pistons and Connecting Rod Overview, Engine Code AWD, page 26 .
AG.
2.6 Pistons and Connecting Rod Overview, Engine Codes AWW and AWP, page 28 .
7 - Bolt
Always replace.
8 - Flywheel/Drive Plate
To remove and install the flywheel, secure using the flywheel retainer -3067- .
Drive plate, removing and installing, refer to 5.4 Drive Plate, page 41 .
9 - Intermediate Plate
Must be located on the alignment sleeves.
Do not damage or bend when doing assembly work.
10 - Sealing Flange with Seal
Only replaced as a complete unit.
To remove and install, remove the oil pan. Refer to 5.1 Oil Pan, page 87 .
Before installing, remove any remaining oil from the crankshaft journal with a clean cloth.
25

Do not additionally oil or grease the sealing lip of the seal.
To install, use the provided support sleeve.
The support sleeve may only be removed after the sealing flange has been slid onto the crankshaft
journal.
2.5
Pistons and Connecting Rod Overview, Engine Code AWD
1 - Piston Rings
Offset gaps by 120.
Use piston ring pliers for
removal and installa
tion.
TOP faces toward the
piston crown.
Checking the ring gap,
refer to
4.1.1 Piston Ring
Gap, Checking,
page 32 .
Checking the piston ring
groove clearance, refer
to
4.1.2 Ring to Groove
Clearance, Checking,
page 32 .
Oil scraping ring, 2 or 3
piece, mixed installation
is permitted.
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spec
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wit
3 - Connecting Rod
Only replace as a set,
Affiliation to the cylinder mark -B-.
Installed location: Marks -A- point to the belt pulley side.
4 - Connecting Rod Bearing Cap
Installed location: Marks -A- point to the belt pulley side.
5 - Nut
Always replace.
Lubricate the threads and contact surface.
Tighten to 30 Nm to measure the radial play, do not tighten the additional torque angle.
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26
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6 - Pressure Relief Valve

27 Nm
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2 - Piston
Checking, refer to
4.1.3 Piston, Check
ing, page 33 .
Mark the installed posi
tion and cylinder alloca
tion.
The arrow on the piston
face points toward the
belt pulley side.
Install using a piston
ring compressor.

Opening pressure: 1.3 to 1.6 bar positive pressure.
7 - Oil Spray Jet
For piston cooling.
8 - Bearing Shell
Note the installed position.
Do not interchange used bearing shells (mark them).
Check for a secure fit in the retaining tabs.
Axial play:
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Wear limit:or0.40
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a radial clearance using Plastigage:
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New: 0.10 to 0.31 mm
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New: 0.01 to 0.05 mm

Wear limit: 0.09 mm
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
Do not rotate the crankshaft when checking the radial clearance.
9 - Cylinder Block
Cylinder bore, checking. Refer to 4.1.4 Cylinder Bore, Checking, page 33 .
Piston and cylinder dimensions, refer to
3.3 Piston and Cylinder Dimensions, Engine Code AWD, page 31 .
10 - Connecting Rod Bolt
Always replace.
11 - Circlip
thi
sd
o
cu
m
en
12 - Piston Pin
If difficult to move, heat the piston to 60 C (140 F).
Removing and installing using a pilot drift -VW 222 A- .
27
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Pistons and Connecting Rod Overview, Engine Codes AWW and AWP
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5 - Connecting Rod
Only replace as a set.
Installed location: Marks -A- points to the belt pulley side.
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4 - Circlip
rrectness of i
t to the co
nform
spec
at
i
h re
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in t
his
3 - Piston Pin
If difficult to move, heat
the piston to 60 C (140
F).
Removing and installing
using a pilot drift -VW
222 A- .
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2 - Piston
Checking, refer to
4.2.3 Piston, Check
ing, page 34 .
Mark the installed posi
tion and cylinder alloca
tion.
The arrow on the piston
face points toward the
belt pulley side.
Install using a piston
ring compressor.
AG. Volkswagen AG d
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1 - Piston Rings
Offset gaps by 120.
Use piston ring pliers for
removal and installa
tion.
TOP faces toward the
piston crown.
Checking ring gap, refer
to
4.1.1 Piston Ring
Gap, Checking,
page 32 .
Check piston ring
groove clearance, refer
to
4.1.2 Ring to Groove
Clearance, Checking,
page 32 .
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6 - Bearing Shell
Note the installed position, refer to Fig. Bearing Shells - Installed Positions , page 29 .
Do not interchange used bearing shells (mark them).
Axial play:
Measure radial clearance using Plastigage:

New: 0.01 to 0.06 mm
Wear limit: 0.09 mm
28
Prote
cted
by
wear limit: 0.37 mm
AG.
New: 0.05 to 0.31 mm

Do not rotate the crankshaft when checking the radial clearance.
7 - Cylinder Block
Cylinder bore, checking, refer to 4.2.4 Cylinder Bore, Checking, page 35 .
Piston and cylinder dimensions, refer to
3.4 Piston and Cylinder Dimensions, Engine Codes AWP and AWW, page 31 .
8 - Connecting Rod Bearing Cap
9 - Oil Spray Jet
For piston cooling.
27 Nm
11 - Connecting Rod Bolt
Always replace.
Lubricate the threads and contact surface.
Use a old bolt to measure radial play.
Tighten to 30 Nm to measure the radial play, do not tighten the additional torque angle.
Bearing Shells - Installed Positions
Bearing shell -1- with a oil bore -arrow- for the
connecting
olkswagenrod.
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Bearing shell -2- without a oil borebfor
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Dimension -a- must be the same on the left and right. Max. devi
ation: 0.2 mm
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Place the bearing shells centered
into the connecting rod
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a
connecting rod cap. ss
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29
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Specifications

3.2 Crankshaft Dimensions, page 30
Engine Code AWD
3.3 Piston and Cylinder Dimensions, Engine Code AWD, page
31
Engine Codes AWP and AWW
3.4 Piston and Cylinder Dimensions, Engine Codes AWP and
AWW, page 31
3.1
Components
Tensioning device for ribbed belt
Center toothed belt cover
Bolt Size
Nm
25
10
Tensioning device for toothed belt 1
Crankshaft Dimensions
Prote
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by
AG.
30
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(Dimensions in mm)
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3.2
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For bolt tightening clarification, refer to

2.1 Belt Drive Overview, page 19 and see items
-14 and 15-
rrectne
s
s
o
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i
t to the co
n
form
spec
atio
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wit
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15
20
Coolant pump
15
Tensioning roller
27
Lower toothed belt cover
10
Pulley for power steering pump
25
Belt pulley/vibration damper
25
Knock sensor
20
Coolant line
20
Oil filter bracket
15 + 90
Oil cooler
25
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Engine speed sensor
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Connecting piece or
15 antee
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Compact bracket
45
ss for generator, air condi
tioning compressor, and power steering
pump
Right engine bracket
45
Oil pump with chain sprocket
15
Bearing cap
65 + 90
Sensor wheel
10 + 90
Crankshaft toothed belt sprocket
90 + 90
Sealing flange
15
Flywheel/drive plate
60 + 90
Sealing flange with seal
15
-Engine Code AWDConnecting rod
30 + 90
Pressure relief valve
27

agen AG
. VolkswMechanical
Engine
- Edition 07.2007
gen AG
d
Crankshaft bearing
pin-diameter
53.75
2nd oversize
53.50
Stage III
53.25
47.30
47.05
Piston and Cylinder Dimensions, Engine

Code AWD
Honing dimen
sion
Piston diameter Cylinder bore di

ameter
Basic dimension
mm
1st oversize
mm
80.965 1
81.01
81.465 1
81.51
Measurement without graphite coating (0.02 mm thick). The

graphite coating wears off.
Piston and Cylinder Dimensions, Engine

Codes AWP and AWW
Prote
cted
by
Piston diameter Cylinder bore di

ameter
Basic dimension
mm
80.965 1
81.01
1st oversize
mm
81.465 1
81.51
AG.
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47.55
-0.022
-0.042
-0.022
-0.042
-0.022
-0.042
-0.022
-0.042
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47.80
rrectness of i
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1st oversize
-0.017
-0.037
-0.017
-0.037
-0.017
-0.037
-0.017
-0.037
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Basic dimension 54.00
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Honing dimen
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Connecting
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Measurement without graphite coating (0.02 mm thick). The

graphite coating wears off.
3. Specifications
31

Diagnosis and Testing
4.1 Engine Code AWD, page 32

4.2 Engine Codes AWW and AWP, page 34
4.1
Engine Code AWD
4.1.1 Piston Ring Gap, Checking, page 32

4.1.2 Ring to Groove Clearance, Checking, page 32
4.1.3 Piston, Checking, page 33
4.1.4 Cylinder Bore, Checking, page 33
4.1.1
Piston Ring Gap, Checking

Feeler Gauge
Insert the ring into the lower end of the cylinder bore at a right
angle from above, approximately 15 mm from the cylinder
edge.
4.1.2
un
le
mm
mm 0.25 to 0.50
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Compression rings
Oil scraping ring
1.00
Ring to Groove Clearance, Checking
32
AG.
compression rings
Oil scraping ring
Ring to groove clearance

New
Wear limit
mm 0.02 to 0.07
0.12
mm 0.02 to 0.06
0.12
Prote
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Piston ring
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Clean the ring groove before checking.
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Feeler Gauge
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Piston ring
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Wear limittho
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0.15 to 0.40
0.8s

4.1.3
Piston, Checking

External Micrometer 75 to 100 mm
Take the measurement approximately 10 mm from the lower edge
of the piston skirt and offset 90 to the piston axis.
Deviation from nominal size: max. 0.04 mm.
4.1.4
Cylinder Bore, Checking

Internal Dial Gauge 50 to 100 mm
Measure diagonally at 3 positions transversely -A- and longi
tudinally -B-.
Deviation from nominal size: Max. 0.10 mm.
Note
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The cylinder bore measurement must not be performed if the cyl

inder block is secured to the assembly stand using the holding
fixture -VW 540- , since inaccurate measurements are possible.
4. Diagnosis and Testing
33
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4.2
Engine Codes AWW and AWP
4.2.1 Piston Ring Gap, Checking, page 34

4.2.2 Ring to Groove Clearance, Checking, page 34
4.2.3 Piston, Checking, page 34
4.2.4 Cylinder Bore, Checking, page 35
4.2.1
Piston Ring Gap, Checking

Feeler Gauge
Insert the ring into the lower end of the cylinder bore at a right
angle from above, approximately 15 mm from the cylinder
edge.
Piston ring
Gap
Compression rings
Oil scraping ring
Wear limit
0.8
. Volkswagen AG
gen AG
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Ring to Groove Clearance, Checking
rrectness of i
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spec
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hole
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4.2.2
New
mm 0.20 to 0.40
mm 0.25 to 0.50

Feeler Gauge
Clean the ring groove before checking.
r
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34
AG.
External Micrometer 75 to 100 mm
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Piston, Checking
Prote
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4.2.3
do
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Compression rings
Oil scraping ring
Ring to groove clearance

New
Wear limit
mm 0.06 to 0.09
0.20
mm 0.03 to 0.06
0.15
ht
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py
Co
t.
Piston ring

Take the measurement approximately 10 mm from the lower edge
of the piston skirt and offset 90 to the piston axis.
Deviation from nominal dimension: Max. 0.04 mm
4.2.4
Cylinder Bore, Checking

Internal Dial Gauge 50 to 100 mm
Measure diagonally at 3 positions transversely -A- and longi
tudinally -B-.
Deviation from nominal size: Max. 0.08 mm.
AG. Volkswagen AG d
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The cylinder bore measurement must notaube
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inder block is secured to the assembly stand
using
the
holding
s
Note
do
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fixture -VW 540- , since inaccurate measurements are possible.
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35
AG.
Prote
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5.1 Ribbed Belt, page 36

5.2 Crankshaft Seal, Ribbed Belt Side, Replacing,
page 37
5.3 Sealing Flange, Belt Pulley Side, page 39
5.4 Drive Plate, page 41
5.1
Ribbed Belt

Locking Pin -T10060 ARemoving
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-arrow- using
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Mark the rotation direction of the ribbed belt.
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Secure the tensioner using the locking pin -T10060 A- .

Remove the ribbed belt.
Installing
Note the previously marked belt rotation direction and be sure
that it is seated correctly on the pulleys.
In vehicles without A/C, lay the ribbed belt last on the generator
last.
In vehicles with A/C, lay the ribbed belt last on the A/C com
pressor last.
After completing the repairs always:

Start the engine and check the belt running.
Ribbed Belt Routing
36
AG.
(generator, Air Conditioning (A/C) compressor, power steering

pump) are secured tightly.
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Installation is in the reverse order of removal.
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Rotate the tensioner in the direction of the

open end wrench until it can be locked.

without A/C
with A/C
Note
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Seal Remover -3203 Counter Support -3415 Assembly Tool -T10053 Torque Wrench (5-50 Nm) -V.A.G 1331 Torque Wrench (40-200 Nm) -V.A.G 1332c
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Remove the ribbed belt and tensioner. Refer to

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Remove the toothed belt. Refer to

5.1 Toothed Belt, page 60 .
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Crankshaft Seal, Ribbed Belt Side, Re

placing
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5.2
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Engines with A/C are equipped with a double ribbed belt.
Remove the toothed belt crankshaft sprocket. To do this, se

cure the toothed belt gear using the counter support -3415- .
37

To guide the seal remover -3203- , thread the bolt into the
crankshaft by hand until seated.
Remove the inner portion of the seal remover -3203- nine ro
tations (approximately 20 mm) from the outer portion and
secure it with the knurled thumb screw.
Lubricate the threaded head of the seal remover -3203- , po

sition it and screw it into the oil seal as far as possible with
olkswagen AG
forced pressure.
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Loosen the knurled thumb screw and turn thed inner
by
against the crankshaft until the oil seal is pulled
out.
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Note
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Installing
does
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Phased in introduction of PTFE seals (Distinguishing features:

without a ring spring, seal lip designed wider). The seal lip of this
seal may not be oiled or greased. An oil seal of the old version
(with ring spring) can be replaced by a PTFE seal - but not the
other way around.
Before installing, remove any remaining oil from the end of the
crankshaft with a clean cloth.
Position the guide sleeve -T10053/1- on the crankshaft.
Slide the seal over the guide sleeve onto the crankshaft.
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38
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Press in the oil seal using the pressure sleeve -T10053- and
bolt -T10053/2- (M16 x 1.5 x 60) until seated.

Install the toothed belt crankshaft sprocket and secure it using
the counter support -3415- .
Tighten the new center bolt to 90 Nm + an additional 90 (1/4)
turn, the additional turn may occur in several stages).
Note
The threads and shoulder must be free of oil and grease.

Install the toothed belt and adjust the valve timing. Refer to
Install the ribbed belt and tensioner. Refer to
5.3
Sealing Flange, Belt Pulley Side

Counter Support -3415 Assembly Tool -T10053-
Hand Drill with Plastic Brush Attachment
Silicone Sealant -D 176 404 A2- (Part numbers are for refer
Protective Glasses
Flat Scraper
Removing
Remove the ribbed belt and tensioner. Refer to

Remove the toothed belt. Refer to
Remove the toothed belt crankshaft gear. To do this, secure

the toothed belt gear using the counter support -3415- .
r
fo
ng
Remove the oil pan. Refer to 5.1 Oil Pan, page 87 .
Remove the sealant residue from the cylinder block with a flat
scraper.
AG.
Remove the sealing flange, and if necessary loosen it by ap

plying light strikes with a rubber hammer.
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Remove the front sealing flange.
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Drain the engine oil.
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Torque Wrench (40-200 Nm) -V.A.G 1332-
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Cover the seal with a clean cloth.
39

Remove any sealant residue from the sealing flange using a
rotating plastic brush (wear safety glasses).
Clean the sealing surfaces. They must be free of oil and
grease.
Installing
Note
Note the expiration date of the sealant.
The sealing flange must be installed within 5 minutes after ap
plication of the sealant.
Cut off the nozzle on the tube of sealant at the front mark (di
ameter of nozzle approximately 3 mm).
Apply the sealant, as shown, to the clean sealing surface of
the sealing flange. The sealant bead must be:
2 to 3 mm thick
and run on the inside of bolt holes -arrowsNote
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The sealant bead must not be thicker, otherwise the excess
sealant could enter the oil pan and may block the oil suction
pipe strainer. Likewise, it could drip onto the sealing surface
of the crankshaft seal.
of the seal with a clean cloth.
rrectness of i
t to the co
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spec
at
i
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in t
his
Before applying the bead of sealant, cover the sealing surface

Set the sealing flange in place immediately and lightly tighten
the bolts.
Note
To position the sealing flange with the seal installed, use the guide
sleeve -T10053/1- .
Tighten the sealing flange bolts in a diagonal sequence. Tight
ening specification: 15 Nm
Prote
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by
40
AG.
After installing, allow the sealant to dry for approximately 30 mi

nutes. Only after then may the engine oil be added.
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Install the oil pan. Refer to 5.1 Oil Pan, page 87 .
do
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Remove any excess sealant.

Install the toothed belt crankshaft sprocket and secure it using
the counter support -3415- .
Tighten the new center bolt to 90 Nm + an additional 90 (1/4)
turn, the additional turn may occur in several stages.
Note
The threads and shoulder must be free of oil and grease.

Install the ribbed belt and tensioner. Refer to
5.4
Drive Plate

Flywheel Lock Adapter -VW 558 M8 x 45 Bolt and two M10 Nuts
Depth Gauge
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Install the flywheel lock adapter a-VW
558- suing the M8 x 45
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bolt to the drive plate. Insert two
s M10 nuts -1- between the
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flywheel lock adapter and drive plate.
Installed location of the flywheel retainer:

-B- to tighten
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spec
atio
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wit
-A- to loosen
Loosen the drive plate bolts.

Installing
Set the drive plate in place, using the washer with notches
-1-.
Insert new bolts -3- and tighten them to 30 Nm.
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41
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Check the dimension -a- at three points and calculate the
mean value. Specified value: 19.5 to 21.1 mm
Note
This is measured through the hole in the drive plate to the ma

chined surface of the cylinder block.
If the specification is not obtained:
Remove the drive plate again and use shim -2-. Tighten the
bolts again to 30 Nm.
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42
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Tighten the bolt to 60 Nm + an additional 90 (1/4) turn, the

additional turn may occur in several stages.

Special Tools

Locking Pin -T10060A-
Flywheel Lock Adapter -VW 558-
rrectness of i
t to the co
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spec
at
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6. Special Tools
43
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Seal Remover -3203 Counter Support -3415 Assembly Tool -T10053 Torque Wrench (5-50 Nm) V.A.G 1331 Torque Wrench (40-200
Nm) -V.A.G 1332-
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44
rrectness of i
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es, in part or in w
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15
Cylinder Head, Valvetrain
General Information
1.1 Cylinder Head, page 45

1.2 Valvetrain, page 45
1.1
Cylinder Head
Note
When using an exchanged cylinder head with the camshaft
installed, the contact surfaces between the lifters and cam

lobes must be lubricated before installing the cylinder head
cover.
The plastic protectors installed to protect the open valves must

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only be removedswimmediately
installing
the cylinder
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replaced.
sa
jection and Ignition; Rep. Gr. 24 ; Description and Operation .
1.2
Valvetrain
Note
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spec
atio
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Intake manifold removing and installing. Refer to Fuel In
Cylinder heads with cracks between the valve seats, or be
tween the valve seat and the spark plug threads, can continue
to be used without reducing the service life, as long as the
cracks have a MAX. width of 0.3 mm, or only the first 4 threads
of the spark plug threads are cracked.
After installing new valve lifters, the engine may not be started
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for approximately 30 minutes. (otherwise valves will strike pis

tons), then turn crankshaft two revolutions.
45
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2.1 Cylinder Head Overview, page 46

2.2 Valvetrain Overview, page 48
2.3 Valve Seats, Refacing, page 51
2.1
Cylinder Head Overview
1 - Cap
2 - Nut
10 Nm
3 - Cylinder Head Cover
AG.
8 - Cylinder Head Gasket

Always replace.
Made of metal
After replacing, replace the entire amount of coolant.
46
Rep. Gr.15 - Cylinder Head, Valvetrain
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7 - Intake Manifold Gasket

Always replace.
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6 - Cylinder Head
Check for distortion, re
fer to
Fig. Checking the
Cylinder Head for Distortion , page 47 .
Resurfacing the sealing surfaces, refer to
Fig. Refacing the Cylinder Head Sealing Surface , page 50 .
Removing and installing, refer to 5.2 Cylinder Head, page 64 .
After replacing, replace the entire amount of coolant.
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
5 - Oil Deflector
Note the installed posi
tion: Above the intake
camshaft.
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4 - Cylinder Head Cover Gas

ket
Replace if damaged.
Before installing, coat
the contact surfaces of
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shaft adjuster/chain ten
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sioner to cylinder head tho
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with sealant -AMV 174
c
s
s
004 01- , refer to
Fig. Double Bearing
Cap Contact Surfaces,
Sealing , page 51
and
Fig. Chain Tension
er or Camshaft Adjuster/
Cylinder Head Contact
Surfaces, Sealing ,
page 51 (Part num
bers are for reference
only. Always check with
your Parts Department
for the latest part num
ber information).

Note the installed position: Identification: Part number must be visible from the intake side.
9 - Toothed Belt
Check for wear.
Do not kink.
Removing, installing and tensioning, refer to 5.1 Toothed Belt, page 60 .
10 - Exhaust Manifold Gasket
Always replace.
11 - Cylinder Head Bolt
Always replace.
Remove and install the polydrive cylinder head bolts using the polydrive bit socket and drive key -3452or -T10070- .
Sequence for loosening and tightening, refer to 5.2 Cylinder Head, page 64 .
12 - Gasket
Replace if damaged.
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Checking the Cylinder Head for Distortion
Feeler Gauge
rrectness of i
t to the co
nform
spec
a
t
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wit
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Straight Edge
es, in part or in w
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Max. permissible distortion: 0.1 mm
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2.2
. Volkswagen AG
Valvetrain Overview
gen AG
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1 - Bolt
10 Nm
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2 - Intake Camshaft
Checking axial play, re
fer to
Fig. Camshaft,
Checking Axial Play ,
page 50 .
Removing and instal
ling, refer to
5.5 Camshaft,
page 71 .
Check the radial clear
ance using Plasti
gage:
Wear limit: 0.1 mm
Run out:
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4 - Bolt
10 Nm
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3 - Drive Chain
tion before removing (in
stalled position), refer to
5.5 Camshaft,
page 71 .
do
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Max. 0.01 mm
5 - O-ring
Always replace.
Only on vehicles with
engine codes AWP and
AWW.
6 - Camshaft Adjustment Valve
1 -N205 Only on vehicles with engine codes AWP and AWW.
Camshaft adjustment, checking. Refer to 4.3 Camshaft, Checking Adjustment, page 57 .
7 - Bolt
3 Nm
Only on vehicles with engine codes AWP and AWW.
8 - Camshaft Adjuster
For vehicles with engine code AWD: Chain tensioner.
Before removing, secure using the bracket for chain adjustment -3366- , refer to
5.5 Camshaft, page 71 .
Camshaft adjustment, checking. Refer to 4.3 Camshaft, Checking Adjustment, page 57 .
9 - Gasket
Always replace.
Made of rubber/metal.
10 - Cylinder Head
Removing and installing, refer to 5.2 Cylinder Head, page 64 .
48
n AG d1999 , Jetta Wagon 1999 , Golf 1998

AG. VolkswageJetta
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Refacing the valve
e o page 51 .
ho seat, refer to 2.3 Valve Seats, Refacing,
ut
ra
a
c
Resurfacingsthe
sealing surfaces, refer to
s
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
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Fig. Refacing the Cylinder Head Sealing Surface , page 50 .

Sealing contact surfaces, refer to Fig. Double Bearing Cap Contact Surfaces, Sealing , page 51
and
Fig. Chain Tensioner or Camshaft Adjuster/Cylinder Head Contact Surfaces, Sealing , page 51 .
11 - Valves
Do not grind, Only hand lapping is permitted.
Valve dimensions, refer to Fig. Valve Dimensions , page 51 .
Exhaust valves with sodium filling: Observe the note for disposal, refer to
Fig. Double Bearing Cap Contact Surfaces, Sealing , page 51 .
12 - Seal
Replacing, refer to 5.3 Camshaft Gear Oil Seal, page 67 .
13 - Hood
For the camshaft position sensor.
Observe the installed location.
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15 - Bolt
25 Nm
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14 - Washer
Conical
16 - Camshaft Position Sensor -G40 Refer to Fuel Injection and Ignition; Rep. Gr. 28 ; Description and Operation .
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17 - Bolt
10 Nm
18 - Bolt
65 Nm
Use the retainer -3036- to loosen and tighten.
19 - Camshaft Sprocket
Note the installed position: Thin rib of the camshaft gear points outward and cylinder 1 Top Dead Center
(TDC) mark is visible.
Note the position when installing the toothed belt, refer to 5.1 Toothed Belt, page 60 .
20 - Seal
Replacing, refer to 5.3 Camshaft Gear Oil Seal, page 67 .
21 - Valve Guide
Checking, refer to 4.4 Valve Guide, Checking, page 59 .
22 - Valve Stem Seal
Replacing, refer to 5.6 Valve Stem Seal, Replacing, page 75 .
23 - Valve Spring
Cylinder head removed: remove and install using the valve spring compressor -3362- .
Cylinder head installed, refer to 5.6 Valve Stem Seal, Replacing, page 75 .
24 - Valve Spring Plate
25 - Valve Retainers
26 - Valve Lifter
Do not interchange.
With hydraulic valve clearance compensation.
Checking, refer to 4.2 Hydraulic Valve Lifters, Checking, page 56 .
Place on the running surface when setting down.
49

Before installing, check the axial play of camshafts, refer to
Fig. Camshaft, Checking Axial Play , page 50 .
Lubricate the contact surface.
27 - Intake Camshaft Bearing Cap
Installation position and installation sequence, refer to 5.5 Camshaft, page 71 .
28 - Double Bearing Cap
Must be located on the alignment sleeves.
Lightly coat contact the surface with sealant -AMV 174 004 01- and follow the installation position and
sequence, refer to 5.5 Camshaft, page 71 .
Seal the contact surfaces of the double bearing cap/cylinder head, refer to
Fig. Double Bearing Cap Contact Surfaces, Sealing , page 51 .
29 - Exhaust Camshaft Bearing Cap
Installation position and installation sequence, refer to 5.5 Camshaft, page 71 .
30 - Exhaust Camshaft
Checking axial play, refer to Fig. Camshaft, Checking Axial Play , page 50 .
Removing and installing, refer to 5.5 Camshaft, page 71 .
Checking the radial clearance using Plastigage:
Wear limit: 0.1 mm
Run out:
Max. 0.01 mm
-a- = at least 139.2 mm
rrectness of i
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Refacing the Cylinder Head Sealing Surface
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The refacing measurement is made via
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Camshaft, Checking Axial Play
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Measure with the valve lifters removed, chain removed and bear
ing caps 2 and 4 installed.
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Dial Gauge
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Dial Gauge Holder -VW 387-
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Wear limit: Max. 0.2 mm
Valve Dimensions
Note
Valves must not be ground. Only hand lapping is permitted.

Dimension
Dia. a
Dia. b
c
mm
mm
mm
Intake valve
Exhaust valve
26.9
5.963
104.84 to 105.34
45
29.9
5.943
103.64 to 104.14
45
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Worn sodium-filled exhaust valves must not be scrapped without

first being properly treated. The valves must be cut in the middle
of the shaft using a metal saw. While doing this, do not come ginto
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contact with water. At the very most, throw 10 of the prepared
not
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valves into a bucket filled with water. Then, move quickly
away,
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Double Bearing Cap Contact Surfaces, Sealing
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Apply a small amount of sealant -AMV 174 004 01- to the con
tact surfaces -arrows- on the double bearing cap. (Part num
bers are for reference only. Always check with your Parts
Department for the latest part number information).
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Apply a small amount of sealant -AMV 174 004 01- to the chain
tensioner/cylinder head or camshaft adjuster/cylinder head
sealing surfaces -arrows-. (Part numbers are for reference on
ly. Always check with your Parts Department for the latest part
number information).
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Chain Tensioner or Camshaft Adjuster/Cylinder Head Contact

Surfaces, Sealing
Valve Seats, Refacing
2.3.1 Intake Valve Seat, Refacing, page 52

2.3.2 Exhaust Valve Seat, Refacing, page 53
Depth Gauge
51
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Engine Mechanical - Edition s07.2007
Valve Seat Refacing Tool
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Note
When repairing engines with leaking valves, it is not sufficient
to reface or replace valve seats and valves. It is also necessary

to check the valve guides for wear. This is particularly impor
tant on high mileage engines. Refer to
4.4 Valve Guide, Checking, page 59 .
Only reface valve seats enough until a perfect contact pattern
is obtained. The maximum permissible refacing dimension

must be calculated before work is carried out. If the reworking
dimension is exceeded, the function of the hydraulic lifters can
no longer be guaranteed and therefore the cylinder head
should be replaced.
Prote
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by
Measure the gap -a- vertically between the valve stem tip and
upper edge of the cylinder head -1-.
Calculate the Max. permissible refacing dimension from the
measured distance and minimum dimension.
Minimum dimensions: Outer intake valve 34.0 mm, center intake
valve 33.7 mm, exhaust valve 34.4 mm
Measured distance minus minimum dimension = Max. permissi
ble refacing dimension.
Example:
Measured distance
- Minimum dimension
= Max. perm. rework dimension
34.4 mm
34.0 mm
0.4 mm
Maximum allowable refacing dimension is represented in il

lustrations for refacing valve seats as dimension b.
2.3.1
Intake Valve Seat, Refacing
Di
men
sion
Intake valve seat
Dia. a
Dia. b
mm
mm
c
Z
mm
52
26.2
Max. permissible rework dimension 1
1.5 to 1.8
Cylinder head lower edge
45 valve seat angle
30 upper correction angle
60 lower correction angle
AG.
If the valve is to be replaced as part of a repair, use a new valve

for the calculation.
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Insert the valve and press it firmly against the seat.
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The maximum permissible refacing dimension is calculated as

follows:

2.3.2
Exhaust Valve Seat, Refacing
Di
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Calculating maximum permissible refacing dimension, refer

to page 52 .
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approximately 1.8
Cylinder head lower edge
45 valve seat angle
30 upper correction angle
60 lower correction angle
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Max. perm. refacing dimension 1 ac
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53
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Specifications
3.1 Fastener Tightening
Bolt Size
Cylinder head cover

Bearing cap for intake camshaft
Nm
10
10
Camshaft adjustment valve 1 1
Camshaft Position Sensor Hood

Camshaft sprocket
1
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fo
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2.2 Valvetrain Overview, page 48 and see items
-4 and 7-
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54
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3
10
25
65
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3.1
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Specifications,
page 54
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4.1 Compression, Checking, page 55

4.2 Hydraulic Valve Lifters, Checking, page 56
Engine Codes AWP and AWW Only
4.3 Camshaft, Checking Adjustment, page 57
4.4 Valve Guide, Checking, page 59
4.1
Compression, Checking

Spark Plug Removal Tool -3122 B Torque Wrench (5-50 Nm) -V.A.G 1331-
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Compression Tester -V.A.G 1763-
55
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wagen
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Engine Mechanical - Edition
07.2007
V
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Removing fuse No. 32 interrupts the voltage supply to the injec

tors.
or
ac
Test Conditions
Engine oil temperature must be at least 30 C (86 F).
Procedure

Disconnect the ignition coil connectors.
Remove the ignition coils.
Remove the spark plugs using the spark plug removal tool
-3122 B- .
Check the compression pressure using the compression test

er -V.A.G 1763- .
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AG.
Note
Using the tester, refer to the operating instructions.

Operate the starter until the ester shows no further pressure
increase.
Compression Pressure
New
bar positive pres
sure
Wear limit
bar positive pres
sure
Difference between
cylinders
bar positive pres
sure
10.0 to 14.0
7.0
Max. 3.0
Install the spark plugs using the spark plug removal tool -3122
B- and tighten them to 30 Nm.
with Engine Code AWD
Install the ignition coils and tighten them to 10 Nm.
with Engine Codes AWP and AWW
Install the ignition coils. Ensure the ignition coils are seated
securely.
Check the Diagnostic Trouble Code (DTC) memory.
Read the readiness code
If the DTC memory was cleared or the Engine Control Module
(ECM) disconnected from the voltage supply, the readiness
code must be regenerated.
4.2
Hydraulic Valve Lifters, Checking

Feeler Gauge
56
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With help from a 2nd technician, have the accelerator pedal

completely pressed.
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Note
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Remove fuse No. 32
b
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au

Wooden or Plastic Wedge
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Replace the complete valve lifter only (cannot be adjusted or
serviced).
Test Sequence
rrectness of i
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Irregular valve noises are normal while starting the engine.
Start the engine and let it run until the coolant fan has turned
on once.
Increase the engine speed to approximately 2500 RPM for 2
minutes.
If the hydraulic valve lifters are still noisy, determine which lifter
or lifters are faulty as follows:
Remove the cylinder head cover.
Rotate the crankshaft clockwise until the camshaft lobe for the
valve lifter to be tested is pointing upward.
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Lightly the press valve lifter downward with a wooded or plastic

wedge. If a 0.20 mm thick feeler gauge can be inserted be
tween the camshaft and valve lifter, replace the valve lifter.
ht
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If the play is greater than 0.2 mm, replace the valve lifter. If
minimal play of 0.1 mm or no play is measured, continue the
procedure as follows:
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Measure the play between the camshaft lobe and valve lifter.
AG.
Prote
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Note
After installing new valve lifters, the engine may not be started for
approximately 30 minutes. The hydraulic equalization elements
must seat themselves (otherwise the valves will crash into the
pistons).
4.3
Camshaft, Checking Adjustment
Only on vehicles with engine codes AWP and AWW

The camshaft adjustment is load and speed dependent. The elec
trical valve for camshaft adjustment switches oil pressure onto
camshaft adjuster (mechanical adjustment mechanisms), which
adjusts the camshaft.
Fault Read Out Device -V.A.G 1551- or Vehicle Diagnosis,
Testing and Information System -VAS 5051 Portable Multi-meter -V.A.G 1526 C Connector Test Set -V.A.G 1594 C Speed Adjuster Tool -V.A.G 1788/10Activation, Checking
First check the camshaft adjuster solenoid valve activation via
the Diagnostic Test Mode (DTM).
If the control is OK:
57

Solenoid Valves, Checking
Measure the resistance between the terminals of the solenoid
valve. Specification: 10 to 18 (at room temperature)
If no malfunctions are found on the valve:
Check the camshaft adjuster function.
Camshaft Adjuster, Checking Function
Test Conditions
Coolant temperature must be at least 85 C (185 F) Display

group 04, display field 3
Test Sequence
Connect the fault read out device -V.A.G 1551- and select the
engine electronics control module with Address word 01.
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Engine must run at idle for this.
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device -V.A.G 1551- and
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(ECM).
n
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Scan tool display:s aut
Initiate basic setting HELP

Enter display group number XXX
Press buttons 0 9 and 4 for Display group number 94 and

confirm entry with Q button.
Scan tool display: (1 to 4 = display fields)
System in basic setting 94 ->
1 2 3 4
Engine code AWW

Adjust the engine speed using the speed adjuster tool -V.A.G
1788/10- to 1800 to 2200 RPM.
Hold the speed at 1800 to 2200 RPM until the display in display
field 3 goes from Test OFF to Test ON.
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Reading results as described:
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Continue to hold the speed at 1800 to 2200 RPM until the

specified value Syst. OK is shown in display field 3.
Remove the speed adjuster tool -V.A.G 1788/10- from the gas
pedal.
Engine code AWP
Press the brake pedal and hold firmly.
Press the gas pedal to Wide Open Throttle (WOT) position.
The engine speed is raised to approximately 2300 RPM by the
ECM.
Hold the brake and gas pedal down until the display in display
field 3 goes from Test OFF to Test ON.
Continue to hold the brake and gas pedal until the specified
value Syst. OK is shown in display field 3.
Reading results as described:
58
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Scan tool display:
rrectness of i
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wit
Press buttons 0 and 4 for function Initiate basic setting and

press Q button to confirm input.
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Quick data transfer HELP

Select function XX
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Jettao1999
, Jetta Wagon 1999 , Golf 1998
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Engine Mechanical - Edition 07.2007or ac
a
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s
Release the brake and gas pedals.

Scan tool display:
Select function XX
rrectness of i
t to the co
nform
spec
at
i
h re
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his
Press key.
Press buttons 0 and 6 for function End output and press

Q button to confirm input.
Turn the ignition off.
If Syst. not OK is shown in display field 3, read out DTC memory.

The following malfunctions can take place with malfunction code
17927:
AG.
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If the DTC memory was cleared or the ECM disconnected from

the voltage supply, the readiness code must be regenerated.
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Read the readiness code.
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Check the DTC memory.
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Replace the camshaft adjuster.
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The camshaft adjuster solenoid valve switches oil pressure cor

rectly on mechanical camshaft adjuster but it cannot reach its end
position (e.g. due to difficulty in moving).
Repeat function test.

If the specified value is not obtained again:
Replace the ECM. Refer to Fuel Injection and Ignition; Rep.
Gr. 24 ; Removal and Installation .
4.4
Valve Guide, Checking

Dial Gauge Holder -VW 387 Dial Gauge
Test Sequence
Insert a new valve into the guide. The valve stem tip must be
flush with the guide. Due to the slight difference in stem di
mensions, ensure that only an intake valve is used in the intake
guide and an exhaust valve in the exhaust guide.
Determine the tilt clearance. Wear limit: 0.8 mm
If the tilt clearance is exceeded:
Replace the cylinder head.
59

5.1 Toothed Belt, page 60

5.2 Cylinder Head, page 64
5.3 Camshaft Gear Oil Seal, page 67
5.4 Camshaft Position Sensor Seal, page 69
5.5 Camshaft, page 71
5.6 Valve Stem Seal, Replacing, page 75
5.1
Toothed Belt

Engine Support Bridge -10-222 A Bracket for Engine -10-222 A/1 Retainer -3180 Tensioning Bolt -T10092 Locking Pin -T40011 Torque Wrench (5-50 Nm) -V.A.G 1331 Torque Wrench (40-200 Nm) -V.A.G 1332-
un
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60
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Liquid Locking Fluid -D 000 600 A2-

Toothed Belt, Tensioning
AG. Volkswagen AG d
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Tension the toothed belt. To do this, remove
ksw the locking pin not
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Rotate the crankshaft twice anduthcheck
if the marks on the
camshaft and crankshaft still salign
with their reference points.
sa
Install the vibration damper bolt. Tightening specification: 25

Nm
rrectness of i
t to the co
nform
spec
at
i
h re
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in t
his
Install the center part of the toothed belt cover (install the bolts
using liquid locking fluid -D 000 600 A2- .) (Part numbers are
for reference only. Always check with your Parts Department
for the latest part number information). Tightening specifica
tion: 10 Nm
Install the toothed belt cover - upper part.
Install the engine mount. Tightening specifications, refer to
2.1 Engine Mount Tightening Specifications, page 5 .
Install the tensioner for the ribbed belt. Tightening specifica
tion: 25 Nm
Install the ribbed belt. Refer to 5.1 Ribbed Belt, page 36 .
Removing

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Observe the rules for cleanliness. Refer to

1.2 Clean Working Conditions, page 110 .
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Read the safety precautions before beginning work. Refer to

1.1 Safety Precautions, page 109 .
AG.
Prote
cted
by
Remove the right headlamp. Refer to Electrical Equipment;

Rep. Gr. 94 ; Removal and Installation .
Remove the air guide pipe between the turbocharger and
charge air cooler.
Remove the ribbed belt tensioning element.
Engine Installed
Position the crankshaft at Top Dead Center (TDC) cylinder 1
(with a manual transmission).
61

Position the crankshaft at TDC cylinder 1 (with a automatic
transmission).
Engine Removed
Position the vibration damper to TDC cylinder 1 -arrows-.

Remove the coolant expansion tank and set aside.
Remove the power steering fluid reservoir and set aside.
Remove the vacuum line to the throttle valve connection.
Remove the upper toothed belt guard.
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Install the engine support bridge -10-222 A- with the bracket

for engine -10-222 A/1- .
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spec
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wit
Engage the retainer -3180- to the right lifting eye and tighten
on cylinder head and lightly pre-tension the engine.
Remove the engine mount bolts -arrows- and completely re

move the mount.
Remove the engine mount bracket from the cylinder block.
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62

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Remove the lower and middle toothed belt
is cover.
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Mark the rotation direction of the toothed
belt.
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Remove the vibration damper.
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Install the tensioning bolt -T10092- into the tensioning device

for the toothed belt.
If necessary, align the pressure piston before tensioning, us
ing needle nose pliers or a thin wire (hole in pressure piston
and hole in housing must line up).
The tension pressure the piston is just enough that the pres
sure piston can be secured using the locking pin -T40011- .
Remove the toothed belt.
AG.
When turning the camshaft, the crankshaft must not be at TDC.

Valves and/or pistons may be damaged.
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Note
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Installing
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Turn the crankshaft back slightly.
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A - Toothed Belt Completely Removed

If the toothed belt was only removed from the camshaft gear, refer
to page 64 .
Conditions
The pistons must not be positioned at TDC.
Procedure
63

Align the mark on the camshaft gear with the mark on the cyl
inder head cover.
Place the toothed belt onto the crankshaft sprocket (observe
the rotation direction).
Install the engine mount bracket to the cylinder block. Tight
ening specification: 45 Nm
Note
Before installing the engine mount bracket, insert the bolts in the
bracket.
Install the toothed belt cover - lower part. (Insert the bolts using
liquid locking fluid -D 000 600 A2- .) (Part numbers are for
reference only. Always check with your Parts Department for
the latest part number information). Torque specification: 10
Nm
Using a bolt, secure the vibration damper (watch locating
point).
Turn the crankshaft to set cylinder 1 at TDC.
Position the toothed belt on the coolant pump, tensioning roller
and camshaft gear.
Tension the toothed belt. Refer to page 61 .
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B - Toothed Belt only Removed from
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Align the mark on the camshaft sprocket with the mark on the
cylinder head cover.
Place the toothed belt on the camshaft gear.
Guide Pins & Handle 1112 mm -3070 Drip Tray -V.A.G 1306- or Drip Tray for VAS 6100 -VAS 6208-
64
AG.
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Cylinder Head
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Tension the toothed belt. Refer to page 61

Torque Wrench (5-50 Nm) -V.A.G 1332 Spring Type Clip Pliers -VAS 5024 A Polydrive Bit and Drive Socket -3452- or -T10070- (engines
with polydrive cylinder head bolts)
Requirements
The engine must be no more than warm to the touch.
Removing
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Read the safety precautions before beginningbwork.
Refer to
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Observe the rules for cleanliness. Refer
to
ss
First, check whether a coded radio is installed. If so, obtain the

anti-theft code.
rrectness of i
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spec
at
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his
With the ignition turned off disconnect the battery Ground

(GND) cable.
Drain coolant. Refer to

WARNING

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Remove the front exhaust pipe from the exhaust manifold or

turbocharger.
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Seal the lines so that the fuel system is not contaminated by

dirt, etc.
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Disconnect the fuel supply and return lines at the connecting

points of the fuel rail.
Disconnect all required connections:

Cooling system
Crankcase ventilation
Secondary Air Injection (AIR) system
Turbocharger/regulation
Fuel injection and ignition system
Remove the ribbed belt tensioning element.
65
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Remove the toothed belt from the camshaft gear. Refer to

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Loosen and remove the cylinder head bolts in the specified

sequence.
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Note
For polydrive cylinder head bolts, use the Polydrive bit and drive
socket -3452- or -T10070- .
Carefully lift the cylinder head off.
Installing
Note
There must be no oil or coolant in the blind holes for the cyl
inder head bolts in the cylinder block.
Only remove the new cylinder head gasket from its packaging
immediately before installing.
Handle the new gasket with extreme care. Damaging will lead
to leaks.
Insert clean cloths into the cylinder bores so that no dirt or

abrasive powder can get between the cylinder wall and piston.
Do not allow dirt or abrasive powder to get into the coolant
either.
Carefully clean the cylinder head and cylinder block sealing
surfaces. Avoid introducing scratches or scoring (do not use
sandpaper with grit below 100).
Carefully remove any metal particles, emery remains and the
cloths.
66
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Bring the camshaft gear to the mark for Top Dead Center
(TDC) cylinder 1 by turning the crankshaft. The mark on the
camshaft gear must align with the arrow -arrow- on the toothed
belt guard.
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Jetta 1999 , Jetta
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Engine Mechanical
- Edition 07.2007
s

To center, install the guide pins -3070- in the cylinder head bolt
holes 8 and 10.
Install the new cylinder head gasket. Text (replacement part
number) must be visible.
Note
Always install new cylinder head bolts.

Install the cylinder head with new bolts, insert the remaining 8
cylinder head bolts and hand tighten.
Remove the guide pins -3070- through the bolt holes using the
guide pin handle. Do this by turning the handle toward the left
until the pins are free.
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Insert both remaining cylinder
head
bolts
and
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head bolts in sequence as follows: or a

c
Tighten all the bolts to 40 Nm.
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Tighten the
au
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Then, tighten all the bolts an additional 90 (1/4) turn using a

wrench.
The rest of the installation is basically a reverse of the removal
sequence.
Fill with new coolant. Refer to

and Testing .
5.3
Camshaft Gear Oil Seal
Prote
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Assembly Tool -T10071-
AG.
Retainer -3036-
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Seal Puller - General Usage -2085-
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Camshaft position sensor gasket removing and installing. Refer

to 5.4 Camshaft Position Sensor Seal, page 69 .
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at
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Then, tighten all the bolts again an additional 90 (1/4) turn.
Torque Wrench (5-50 Nm) -V.A.G 13315. Removal and Installation
67

Torque Wrench (40-200 Nm) -V.A.G 1332Removing
camshaft gear must be flush with the mark on the cylinder
head cover.
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Remove the camshaft sprocket. To loosen the bolt,

hold the camshaft gear using the retainer -3036- .
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Insert the camshaft gear bolt -arrow- into the camshaft by hand
to the stop to guide the seal puller.

without a ring spring, the seal lip is designed wider). The seal lip
of this seal may not be oiled or greased. An oil seal of the old
version (with a ring spring) can be replaced by a PTFE seal - but
not the other way around.
Before installing, remove any remaining oil from the camshaft
journal with a clean cloth.
68
Prote
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AG.
Installing
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Loosen the knurled thumb screw and turn the inner part
against the camshaft until the seal is removed.
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Lubricate the threaded head of the seal puller - general usage

-2085- , position and screw it into the oil seal as far as possible
with forced pressure.
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Remove the inner portion of the seal puller - general usage

-2085- two rotations (approximately 3 mm) from the outer por
tion and secure it with the knurled thumb screw.

Install the guide sleeve -T10071/1- on the camshaft.
Slide the oil seal over the guide sleeve onto the camshaft.
Press in the seal until seated using the thrust sleeve T10071/3- . To do so, use the bolt -T10071/4- .
The rest of installation is in the reverse order of removal.
5.4
Camshaft Position Sensor Seal

Seal Remover - General Usage -2085 Seal Installer -3241- (for standard version seal with ring
spring)
Assembly Tool -T10071- (for PTFE version of seal)
Torque Wrench (5-50 Nm) -V.A.G 1331 Torque Wrench (40-200 Nm) -V.A.G 1332 M8 x 60 Bolt
Removing
Disconnect the connector from the Camshaft Position (CMP)

sensor -arrow-.
Remove the housing for the sensor.
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Remove the washer and cover for the sensor.
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69
AG.
Prote
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To guide the seal puller - general usage -2085- , thread the
adapter -2085/1- in the camshaft by hand until seated.
Remove the inner portion of the seal puller - general usage
-2085- two rotations (approximately 3 mm) from the outer por
tion and secure it with the knurled thumb screw.
Lubricate the threaded head of the seal pullet, position it and

with forced pressure screw it into the oil seal as far as possible.
Loosen the knurled thumb screw and turn the inner part
against the camshaft until the seal is removed.
Installing
Note

without a ring spring, seal lip is designed wider). The seal lip of
this seal may not be oiled or greased. An oil seal of the old version
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(with a ring spring) can be replaced by a PTFE seal - but
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PTFE Seal, Installing
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Place the guide sleeve -T10071/5- on the camshaft.

Slide the seal over the guide sleeve -T10071/5- .
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Lightly oil the sealing lip of the seal.
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Seal (with a ring spring), Installing
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Press in the seal until seated using the thrust sleeve T10071/3- . Use a M8 x 60 bolt -1- for this.
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spec
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Before installing, remove any remaining oil from the camshaft

journal with a clean cloth.

Place the guide sleeve -3241/2- on the camshaft.
Slide the seal over the sleeve -3241/2- .
Insert the CMP sensor trim with notch in the intake camshaft.
Install the washer (with cone outward) and tighten the bolt to
25 Nm.
Install the CMP sensor housing and tighten it to 10 Nm.
Install the toothed belt cover - upper section.
Connect the connector to the CMP sensor -arrow-.
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5.5
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Press in the seal until seated using the thrust sleeve -3241/1- .
To do so, use the bolt -3241/3- .
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Camshaft
(with the cylinder head installed)

Retainer -3036 Bracket for Chain Adjustment -3366 Torque Wrench (5-50 Nm) -V.A.G 1331 Torque Wrench (40-200 Nm) -V.A.G 1332 Sealant -AMV 174 004 01- (Part numbers are for reference
only. Always check with your Parts Department for the latest
part number information).
Sealant -D 454 300 A2- (Part numbers are for reference only.
Always check with your Parts Department for the latest part
number information).
Removing
71

camshaft gear must be flush with the mark on the cylinder
head cover.
Remove the camshaft sprocket. To loosen the bolt, counter
hold the camshaft gear using the retainer -3036- .
Remove the sensor housing.
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Clean the drive chain and camshaft chain sprockets -arrowsacross both bearing caps and mark the installed position with
a colored mark.
Note
Do not mark the chain using a center punch or similar means!

The distance between both -arrows- of the colored marks con
sists of 16 rollers of the drive chain.
Prote
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72
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Hydraulic chain tensioner can be damaged if the bracket for chain

adjustment -3366- is tightened too hard.
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Note
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Secure the camshaft adjuster or chain tensioner using the

bracket for chain adjustment -3366- .
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form
spec
atio
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Remove the washer and cover for the sensor. Volkswa

swagen AG
n AG. VolkMechanical
doe-sEdition 07.2007
ageEngine
ksw
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ex
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Remove both bearing caps from the chain sprocket on the in

take and exhaust camshafts.
Remove the bolts for the camshaft adjuster/chain tensioner.
Alternating in a diagonal sequence, loosen the bearing caps
2 and 4 of the intake and exhaust camshafts and remove.
Remove the intake and exhaust camshafts with a camshaft
adjuster or chain tensioner and bracket for chain adjustment
-3366- .
Installing
Note
When installing the camshafts, the cam lobes for cylinder 1
must point upward.
When installing the bearing caps, verify the mark on the cap
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Place the drive chain onto both camshaft sprockets according

to the colored marks.
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is readable from the intake side of the cylinder head.
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atio
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Remove the double bearing cap.
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First, remove bearing caps 3 and 5 from

haust camshafts.
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the intake
and
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AG.
Note
When using a new drive chain, the distance between notches
-A and B- must be 16 rollers of the chain.
Illustration shows where the first and sixteenth drive chain roll
ers must be installed on the chain gears.
Notch -A- is slightly offset inward toward the chain roller -1-
Replace the rubber/metal seal for the camshaft adjuster or

chain tensioner and coat the hatched surface with a thin coat
ing of sealant -D 454 300 A2- . (Part numbers are for reference
Insert the camshaft adjuster/chain tensioner between the drive
chain.
Oil the running surfaces of both camshafts.
Insert the camshafts with drive chain and camshaft adjuster/
chain tensioner into the cylinder head.
Tighten the camshaft adjuster/chain tensioner to 10 Nm (pay
attention to the bushing).
73

Alternating in a diagonal sequence, tighten the bearing caps
2 and 4 of the intake and exhaust camshafts and tighten to 10
Nm (pay attention to the bushing).
Install both bearing caps on the chain gears of the intake and
exhaust camshafts. Check the camshaft for proper adjustment
and tighten the bearing cap to 10 Nm (pay attention to align
ment bushing).
Remove the bracket for chain adjustment -3366- .
Coat the hatched surface of the double bearing cap lightly us

ing sealant -AMV 174 004 01- , install and tighten to 10 Nm
(pay attention to the bushing). (Part numbers are for reference
Install the remaining bearing cap and tighten to 10 Nm (pay
attention to the alignment bushing).. Volkswag
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74
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spec
atio
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wit
Install the camshaft gear (thin rib toward the outside and TDC
mark visible) and tighten the bolt to 65 Nm (use the retainer
-3036- ).
thi
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Check the position of the camshafts -arrows- to each other
again.
The rest of the installation is basically a reverse of the removal.
Note
After installing new valve lifters, the engine may not be started for
approximately 30 minutes. The hydraulic equalization elements
must seat themselves (otherwise the valves will crash into the
pistons).
5.6
AG. Volkswagen AG d
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Valve Stem Seal, Replacing

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(with the cylinder head installed)

Spark Plug Removal Tool -3122 B-
rrectness of i
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Valve Spring Compressor -3362- and Thrust Piece -3362/1 Valve Seal Removal Tool -3364 Pressure Hose -VW 653/3-
Torque Wrench (5-50 Nm) -V.A.G 1331 Torque Wrench (40-200 Nm) -V.A.G 1332 Valve Stem Seal Driver -3365Removing
Remove the camshafts. Refer to 5.5 Camshaft, page 71 .
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Move the piston for the respective cylinder to the Bottom Dead
Center (BDC) position.
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Remove the spark plugs using the spark plug removal tool
-3122 B- .
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Remove the valve lifters and place them on the contact surface
when setting them down. Be careful not to switch the valve
lifters.
75
AG.
Jetta 1999 , Jetta Wagon 1999 , Golf 1998 . Volkswage

n AG d
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Engine Mechanical - Edition 07.2007 olkswagen
no
Install the pressure hose -VW
threads.
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Place the thrust piece -3362/1- into the valve spring compres
sor -3362- .
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Using the bolts bolted in the tool, secure the valve spring com
pressor -3362- to the cylinder head.
Bring the valve spring compressor -3362- into the following
position to press the valve springs together
Outer intake valves: Lower position
Center intake valve: Upper position

Exhaust valve: Lower position
Connect the compressed air hose to a pressure of at least 6

bar and then remove the valve springs.
Remove the valve stem seals using the valve stem removal
tool -3364- .
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Oil the sealing lip of the valve stem oil seal -B-, insert it into
the valve stem seal driver -3365- and carefully slide it onto the
valve guide.
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Place the plastic sleeve -A- on the valve stem to prevent dam
age to new the valve stem oil seal.
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Installing

Special Tools

Bracket for Engine -10-222 A/1 Spark Plug Removal Tool -3122 B Valve Spring Compressor -3362 Valve Seal Removal Tool -3364 Pressure Hose -VW 653/3 Engine Support Bridge -10-222 A Retainer -3180 Tensioning Bolt -T10092 Locking Pin -T40011-
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Spring Type Clip Pliers -VAS 5024 A-
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Drip Tray -V.A.G 1306-
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Guide Pins & Handle 1112 mm -3070-
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Polydrive Bit and Drive Socket -3452 Seal Puller - General Usage -2085 Seal Installer -3241 Assembly Tool -T10071-
Compression Tester -V.A.G 1763-
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Valve Stem Seal Driver -3365-
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Dial Gauge Holder -VW 387-
6. Special Tools
77

Retainer -3036 Bracket for Chain Adjust
ment -3366 Torque Wrench (5-50 Nm) V.A.G 1331 Torque Wrench (40-200
Nm) -V.A.G 1332-
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17
Lubrication
General Information
1.1 Engine Oil, page 79

1.2 Lubrication System, page 79
1.1
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Oil System Capacity
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For the oils aucapacity, refer to Fluid Capacity
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1.2
Lubrication System
Note
If large quantities of metal particles or abraded material are
detected during engine repairs, it may be an indication for a

damaged crankshaft or rod bearings. To prevent further dam
age, perform the following steps after the repair:
Carefully clean the oil passages

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Replace the oil injection jets

Replace the oil cooler
do
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Replace the oil filter
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spec
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Use engine oil conforming to VW standard 502 00. Only in ex

ceptional circumstances: Multi-grade oils corresponding to APISF or SG.
The oil level must not be above the Max. mark - danger of
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damage to catalytic converter! Marks, refer to

Fig. Marks on the Oil Dipstick , page 82 .
79
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2.1 Lubrication System
Lubrication System Components
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3 - Chain Tensioner with Ten

sioning Rail
15 Nm
Check for wear.
When installing, preten
sion the spring and in
stall.
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2 - Sealing Flange
Must be located on the
alignment sleeves.
Clean the sealing sur
face before installing.
Install using silicone
sealant -D 176 404 A2(Part numbers are for
reference only. Always
check with your Parts
Department for the lat
est part number infor
mation).
Removing and instal
ling, refer to
5.3 Sealing Flange,
Belt Pulley Side,
page 39 .
rrectness of i
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1 - Bolt
15 Nm
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2.2 Oil Filter Housing Overview, page 82
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Components,
page 80
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4 - Chain Sprocket
For the oil pump drive.
Check for wear.
5 - Cylinder Block
Crankshaft overview,
refer to
2.3 Crankshaft Over
view, page 23 .
Piston and connecting rod overview, refer to one of the following:
2.5 Pistons and Connecting Rod Overview, Engine Code AWD, page 26 .
2.6 Pistons and Connecting Rod Overview, Engine Codes AWW and AWP, page 28 .
6 - Oil Dipstick
The oil level must not be above the Max. mark!
Marks, refer to Fig. Marks on the Oil Dipstick , page 82 .
7 - Inlet Spout
For the oil dipstick.
For extracting oil.
80
Rep. Gr.17 - Lubrication

8 - Guide Tube
9 - Oil Spray Jet
For the piston cooling.
27 Nm
11 - Bolt
15 Nm
12 - Suction Pipe
Clean the strainer if dirty.
13 - O-ring
Always replace.
14 - Splash Wall
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15 - Bolt
15 Nm
Loosen and tighten using the T-bar and socket 10 mm -3185- .
Remove using socket -3249- .
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17 - Oil Drain Plug

30 Nm
If the sealing ring is leaking cut if off and replace it.
18 - Gasket
Always replace.
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20 - Bolt
10 Nm
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19 - Oil Return Pipe

From the turbocharger.
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16 - Oil Pan
Clean the sealing surface before installing.
Install using silicone sealant -D 176 404 A2- (Part numbers are for reference only. Always check with
your Parts Department for the latest part number information).
Removing and installing, refer to 5.1 Oil Pan, page 87 .
21 - Oil Pump
With the pressure relief valve, 12 bar.
Before installing, check to be sure both alignment bushings are present (for centering oil pump/cylinder
block).
Replace if the contact surfaces and gears are scored.
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22 - Chain Sprocket
For oil pump.
Check for wear.
23 - Bolt
25 Nm
24 - Roller Chain
Check for wear.
25 - Alignment Sleeves
Check for secure seating.
81
1 - MAX. mark
2 - MIN. mark
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a - Area above the hatched field up to the MAX. mark: Do not add
engine oil!
b - Oil level within the hatched field: Engine oil can be added.
c - Area from the MIN. mark up to the hatched field: Add a Max.
0.5 liter of engine oil!
2.2
Oil Filter Housing Overview
1 - Locking Bolt
40 Nm
Prote
cted
by
5 - Gasket
Always replace.
6 - Return Flow Check Valve
8 Nm
7 - Seal
Slide up to the collar of
the tube.
Replace if damaged.
8 - Connecting Pipe
For the crankcase ven
tilation.
9 - Retaining Clip
Check for secure seat
ing.
10 - Locking Bolt
15 Nm
11 - Seal
If the seal is leaking cut it off and replace it.
12 - Bolt
20 Nm
13 - Oil Supply Pipe
To the turbocharger.
82
AG.
4 - Piston
For the pressure relief
valve, approximately
4 bar.
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3 - Spring
For the pressure relief
valve, approximately
4 bar.
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2 - Seal
If the seal is leaking cut
it off and replace it.
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Marks
AG. Volkswagen AG d
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V 1999 , Golf 1998
Jetta 1999 , Jetta Wagon
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Engine Mechanical - oEdition
07.2007
ris
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on the Oil Dipstick s

14 - Banjo Bolt
30 Nm
15 - Gasket
Always replace.
16 - Oil Pressure Switch -F1 25 Nm
Black, 1.4 bar
Checking, refer to 4.1 Oil Pressure and Oil Pressure Switch, Checking, page 85 .
17 - Seal
If the seal is leaking cut it off and replace it.
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19 - Gasket
Always replace.
Snaps into the tabs of the oil cooler.
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18 - Bolt
Always replace.
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spec
a
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21 - Nut
25 Nm
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20 - Oil Filter Element

Remove using a tension strap.
Tighten by hand.
Observe the installation instructions for the oil filter.
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23 - Oil Filter Bracket

With the pressure relief valve, approximately 4 bar.
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22 - Oil Cooler
Ensure sufficient clearance to surrounding components.
See the note in the 1.2 Lubrication System, page 79 .
Coat the contact surfaces to the oil filter bracket outside seal with sealant -AMV 188 100 02- . (Part
numbers are for reference only. Always check with your Parts Department for the latest part number
information).
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83
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Specifications
3.1
Components
Sealing flange
Pressure relief valve
Oil pan
Oil drain plug
Oil return pipe
Chain sprocket
Chain tensioner with tensioning rail
Bolt Size
Nm
15
27
15
30
10
25
15
40
15
25
15 + 90
8
30
25
Oil filter bracket 1
Return flow check valve

Oil supply pipe
Oil cooler
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For bolt tightening clarification,
refer to
no
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V
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2.2 Oil Filter Housing
Overview,
page
82
and
seet items
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4.1 Oil Pressure and Oil Pressure Switch, Checking,

page 85
4.1
Oil Pressure and Oil Pressure Switch,

Checking

Oil Pressure Gauge -V.A.G 1342 Voltage Tester -V.A.G 1527 B-
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Connector Test Set -V.A.G 1594 CyV
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Test Conditions
h
t
or
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s
Engine oil level OK, checking. Refer to
Fig. Marks on the Oil Dipstick , page 82 .
Engine oil temperature at least 80 C (176 F) (coolant fan

must start up once)
rrectness of i
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spec
atio
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Note
Function test and servicing the optical and acoustic oil pressure
indicator: Refer to Wiring diagrams, Troubleshooting & Com
ponent locations.
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Test Sequence
Remove the oil pressure switch and install it into the oil pres
sure gauge.
Install the oil pressure gauge -V.A.G 1342- into the oil filter
bracket in place of the oil pressure switch.
Connect the brown wire from the tester to Ground (GND).
Connect the voltage tester -V.A.G 1527 B- using an adapter
cable from the connector test set -V.A.G 1594 C- to B+ and
the oil pressure switch. The Light Emitting Diode (LED) must
not light up.
If the LED lights up, replace the oil pressure switch.
If the LED does not light up:
Start the engine and let run at idle: The LED must light up at
1.2 to 1.6 bar positive pressure, otherwise replace the oil pres
sure switch.
Check the oil pressure at different speeds:
2000 RPM: 2.7 to 4.5 bar
Above 2000 RPM: maximum 7.0 bar
If the specifications are not obtained:
Correct the mechanical damage, for example, bearing dam
age.
Replace the oil filter bracket with pressure relief valve or oil
pump.
. Volkswagen AG
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At higher engine speeds the oil pressure must not exceed 7.0 bar
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Check the oil passages.
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86
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If necessary, replace the oil filter bracket with pressure relief

valve.
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If the specification is exceeded:

5.1 Oil Pan, page 87
5.1
Oil Pan

T Bar and Socket 10 mm -3185 Socket -3249 Torque Wrench (5-50 Nm) -V.A.G 1331 Silicone Sealant -D 176 404 A2- (Part numbers are for refer
Hand Drill with Plastic Brush Attachment
Protective Glasses
Flat Scraper
Removing
Drain the engine oil.
Note
Observe disposal regulations!
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Remove the turbocharger oil return pipe from the oil pan.
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Loosen the oil pan bolts using the T-bar and socket 10 mm
-3185- . (Remove using the socket -3249- .)
rrectness of i
t to the co
nform
spec
a
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i
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wit
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s
Remove the oil pan. Loosen the oil pan with light blows using
a rubber mallet, if necessary.
Remove any sealant residue from the cylinder block with a flat
scraper.
Remove any remaining sealant from the oil pan using a rotat
ing brush, for example, a drill with a plastic brush attachment
(wear protective glasses).
Installing
Note
Note the expiration date of the sealant.
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of the sealant.
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The oil pan must be installed within 5 minutes after application
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Clean the sealing surfaces. They must be free of oil and

grease.
87

Cut off the nozzle on the tube of sealant at the front mark (dia.
of the nozzle approximately 3 mm).
Apply the sealant to the clean sealing surfaces of the oil pan
as shown. The sealant bead must be:
2 to 3 mm thick
and run on the inside of bolt holes -arrows. Volkswagen AG
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Note
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rrectness of i
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spec
atio
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Apply the silicone sealant -D 176 404 A2- to the clean sealing
surface as indicated in the illustration. (The fig. shows the lo
cation of the sealant bead on the cylinder block). (Part num
bers are for reference only. Always check with your Parts
Department for the latest part number information).
Install the oil pan immediately and tighten all the oil pan bolts
lightly.
Note
After installing the oil pan, allow the sealant to dry for approxi
mately 30 minutes. Only after then may the engine oil be added.
Tighten the oil pan bolts to 15 Nm.
Prote
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AG.
88
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Tighten the oil pan to oil return line bolts to 10 Nm.
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Tighten the oil pan to transmission bolts to 45 Nm.
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The sealant bead must not be thicker than specified. Otherwise,

the excess sealant could get into the oil pan and clog the strainer
in the intake line of oil pump.
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Special Tools

Torque Wrench (5-50 Nm) -V.A.G 1331 T-Bar and Socket 10 mm -3185-
Socket -3249-
rrectness of i
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nform
spec
at
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6. Special Tools
89
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Oil Pressure Gauge -V.A.G
1342 Voltage Tester -V.A.G 1527
B-
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Connector Test Set -V.A.G

1594 C-

19
Cooling System
General Information
AG. Volkswagen AG
n Components,
1.1 Cooling System
page
doe 91
wage
s no
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1.2 Cooling
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1.1
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Cooling System Components
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Caution

is followed.
Ensure sufficient clearance to all moving or hot compo
nents.
WARNING
rrectness of i
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spec
atio
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wit

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Note
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Hot steam may escape when opening the expansion tank.

Wear protective goggles and protective clothing to prevent
damage to eyes and scalding. Cover the cap with a cloth and
open very carefully.
When the engine is warm the cooling system is under pres
sure. If necessary release pressure before beginning repair

work.
Hoses are secured with spring type clamps. In cases of repair
only use spring type clamps.
Hose clip pliers -V.A.G 1921- or spring type clip pliers -VAS
5024 A- are recommended for installing spring clamps.
When installing coolant hoses, make sure they are free of
stress and do not come into contact with other components

(observe the marks on the coolant connections and hoses).
Perform a cooling system leakage test using the cooling system

tester -V.A.G 1274- and adapters -V.A.G 1274/8- and -V.A.G
1274/9- .
1.2
Cooling System, Draining and Filling

Refractometer -T10007 Drip Tray -V.A.G 1306- or Drip Tray for VAS 6100 -VAS 6208 Spring Type Clip Pliers -VAS 5024 A Cooling System Charge Unit -VAS 6096-
91

Draining
WARNING

Open the cap for coolant expansion tank.
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Rep. Gr.19 - Cooling System
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Open the drain plug -arrow- to drain the coolant from the ra
diator.

In addition, to drain the coolant from the engine, disconnect
the coolant hose at the oil cooler -arrow-.
Note
Observe disposal regulations!

Filling
Note
Only use coolant additive G 12 (according to TL VW 774 D).
Distinguishing feature: red color
n AG. Volkswagen AG dounder

G 12 must not be mixed with anysother
es
wage coolant additives
any circumstances!
G 12 and coolant additives marked in accordance with TL
rrectness of i
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spec
at
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VW 774 D prevent frost and corrosion damage, scaling and

also raise the boiling point of the coolant. For this reason the
system must be filled all year round with frost and corrosion
protection additives.
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Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop

ical climates.
Protection against frost must be assured to about -25 C (-13
F) (in arctic climatic countries to about -35 C (-31 F)).
The coolant concentration must not be reduced by adding
clean water even in warmer seasons and in warmer countries.

The coolant additive portion must be at least 40%.
If for climatic reasons a greater frost protection is required, the
amount of G 12 can be increased, but only up to 60% (frost

protection to about -40 C (-40 F), as otherwise frost protec
tion is reduced again and cooling effectiveness is also re
duced.
The refractometer -T10007- is recommended for determining

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If the radiator, heater core, cylinder head or cylinder head

Prote
cted
by
Frost protection Anti-freeze por

to
tion
-25 C (-13 F)
-35 C (-31 F)
40%
50%
AG.
Recommended Mixture Ratios
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gasket is replaced, do not reuse the old coolant.
G 12 1
Clean water
2.0 l
2.5 l
3.0 l
2.5 l
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anti-freeze density.
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o
The fluid in the reservoir
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coolant. In this case,
c
ss
The quantity of coolant can vary depending upon vehicle

equipment.
93

Tighten the drain plug in the radiator.
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Push the coolant hose onto the oil cooler connection and fas
ten with the spring type clamp -arrow-.
Using the Cooling System Charge Unit -VAS 6096 Install the adapter from the cooling system tester -V.A.G 1274that is appropriate for the vehicle on the expansion tank.
Fill the coolant circuit using the cooling system charge unit VAS 6096- . Refer to the Operating instructions fro the cooling
system charge unit.
Without Using the Cooling System Charge Unit -VAS 6096-
Fill the coolant to the MAX. mark on the expansion tank.
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94
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From Model Year 2002 Vehicles
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Through Model Year 2001 Vehicles

Slowly fill the coolant up to the top mark of the hatched area
on the expansion tank.
Seal the expansion tank.
Turn off the heater and Air Conditioning (A/C).
Start the engine and maintain an engine speed of about 2000
RPM for approximately 3 minutes.
Allow the engine to run until the fan turns on.
WARNING

Through Model Year 2001 Vehicles
Check the coolant level and top off if necessary. With the en
gine at operating temperature, the coolant level must be at the
MAX. mark, with the engine cold, it must be between the MIN.
and MAX. marks.
From Model Year 2002 Vehicles
With the engine at operating temperature, the coolant level must
lie at the top mark of the hatched area.
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When the engine is cold, the coolant level should be somewhere
db
ise
r
in the middle of the hatched area.
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2.1 Coolant Hose Connection Diagram, page 96
olkswagen AG
en AG. V
does
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Engine Side,
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2.2 Cooling System Components Overview, Body
ksw Side, page
Vol
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99
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2.1
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2.3 Cooling System Components Overview,
au
s
page 100
s
Coolant Hose Connection Diagram
2.1.1 Engine Code AWD, page 96
rrectness of i
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2.1.2 Engine Code AWP with a Manual Transmission and

AWW with a Manual and Automatic Transmission, page 97
2.1.3 Engine Code AWP with a Automatic Transmission, page
98
2.1.1
Engine Code AWD
1 - Radiator
2 - Oil Cooler
3 - Coolant Thermostat Hous

ing
10 - Lower Coolant Pipe

11 - Intake Manifold
12 - Drain Plug
96
Prote
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by
9 - Transmission Oil Cooler

Only with a automatic
transmission.
AG.
8 - Connecting Piece
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7 - Heater Core
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6 - Turbocharger
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5 - Expansion Tank
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4 - Cylinder Head/Cylinder
Block

2.1.2
Engine Code AWP with a Manual Transmission and AWW with a Manual
and Automatic Transmission
1 - Expansion Tank
2 - Turbocharger
3 - Intake Manifold
Block
6 - Heater Core
Only with engine code
AWW with a automatic
transmission.
9 - Upper Coolant Hose
10 - Drain Plug
11 - Radiator
12 - Lower Coolant Hose
13 - Oil Cooler
14 - Coolant Thermostat Hous
ing
15 - Coolant Pump
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16 - Coolant Pipe
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97
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2.1.3
Engine Code AWP with a Automatic Transmission
1 - Expansion Tank
2 - Turbocharger
3 - Intake Manifold
Block
5 - Coolant Pipe
7 - Heater Core
Only with a automatic
transmission.
10 - Oil Cooler
12 - Radiator
14 - After-Run Coolant Pump V5115 - Coolant Thermostat Hous
ing
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98
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16 - Coolant Pump

Cooling System Components Overview, Body Side
1 - Radiator
Removing and instal
ling, refer to
5.1 Radiator,
page 104 .
After replacing, replace
the entire amount of
coolant.
9 - Connector
10 - Fan
pe
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itte
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AG.
8 - Retaining Clip
Check for secure seat
ing.
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7 - Bracket
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6 - Auxiliary Fan
optional equipment.
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5 - Bolt/Nut
10 Nm
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4 - Fan Shroud
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Secured to the radiator
with a retaining clip.
Ensure it is seated se
curely.
Coolant hose connec
tion diagram, refer to
2.1 Coolant Hose
Connection Diagram,
page 96 .
un
le
2 - O-ring
Replace if damaged.
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2.2
11 - Bracket
For the fan connector.
Secured to the radiator with a retaining clip.
Ensure it is seated securely.
Coolant hose connection diagram, refer to 2.1 Coolant Hose Connection Diagram, page 96 .
13 - O-ring
Always replace.
14 - Coolant Fan Control Thermal Switch -F18 35 Nm
For the electric fan.
Switch temperatures:
1st stage on: 92 to 97 C (198 to 206 F), off: 84 to 91 C (183 to 196 F).
2nd stage on: 99 to 105 C (210 to 221 F), off: 91 to 98 C (196 to 208 F).
15 - Bracket
For the radiator.
99

16 - Bolt
15 Nm
2.3
Cooling System Components Overview, Engine Side
1 - Bolt
15 Nm
2
es n
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- Toothed Belt
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ris
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or
tion before removing.
u
ac
a
ss
3 - Coolant Pump
Check for ease of move
ment.
If damaged or leaking
replace completely.
Removing and instal
ling, refer to
5.2 Coolant Pump,
page 104 .
4 - O-ring
Always replace.
r
fo
ng
ht
rig
py
Co
t.
5 - Coolant Thermostat
Checking: Heat up the
thermostat in water.
Opening begins approx
imately 87 C (188 F).
Ends approximately 102
C (216 F).
Opening lift a MIN. of 7
mm.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
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Check for wear.

Do not kink.
Removing, installing
and tensioning, refer to
5.1 Toothed Belt,
page 60 .
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6 - O-ring
Always replace.
8 - to the Heater Core
9 - O-ring
Always replace.
10 - Connector
4 pin
11 - Engine Coolant Temperature Sensor -G62 With the engine coolant temperature gauge sensor -G2- .
For the Engine Control Module (ECM).
If necessary, release the pressure in the cooling system before removing.
100

Checking, refer to Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis and Testing .
12 - Retaining Clip
15 - Oil Cooler
16 - from the Heater Core
18 - Bolt
10 Nm
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20 - Seal
Replace if damaged.
21 - Bolt
10 Nm
rrectne
s
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form
spec
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19 - Cap
Check using the cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/9- .
Test pressure: 1.4 to 1.6 bar positive pressure.
22 - Expansion Tank
Perform the cooling system leakage test using the cooling system tester -V.A.G 1274- and adapter V.A.G 1274/8- .
23 - to the Turbocharger
24 - Bolt
15 Nm
ht
rig
py
Co
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r
fo
ng
25 - to the Top Coolant Hose

Only on engine code AWP with a automatic transmission.
26 - After-Run Coolant Pump -V51 Only on engine code AWP with a automatic transmission.
Checking, refer to 4.1 After-Run Coolant Pump, Checking, page 103 .
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27 - from the Turbocharger

Only on engine code AWP with a automatic transmission.
101

Specifications
Components
Bolt Size
Nm
10
35
15
15
10
10
15
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102
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spec
a
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Fan shroud
Coolant Fan Control Thermal Switch -F18Bracket for radiator
Toothed belt
Lower coolant line
Expansion tank
Connecting piece
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3.1

4.1 After-Run Coolant Pump, Checking, page 103
4.1
After-Run Coolant Pump, Checking

Voltage Tester -V.A.G 1527 B Connector Test Set -V.A.G 1594 C Wiring Diagram
Test Conditions
All fuses must be OK.
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Test Sequence
es, in part or in w
l purpos
hole
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Disconnect the 2-pin connector from the after-run coolant

pump -V51- .
rrectness of i
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nf
o
r
m
spec
atio
h re
n in
wit
Connect the contacts from the after-run coolant pump to the

battery, using adapter cables from the connector test set V.A.G 1594 C- . The after-run coolant pump must start run
ning.
If the after-run coolant pump does not start running:
If the after-run coolant pump does starts running:
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Connect the voltage tester -V.A.G 1527 B- to the disconnected

connector of the after-run coolant pump, using adapter cables
from the connector test set -V.A.G 1594 C- . The Light Emitting
Diode (LED) must light up.
ht
rig
py
Co
t.
Turn the ignition off and then on again.
thi
sd
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en
Replace the after-run coolant pump.
Note
This test must be performed inside of 5 min. after the ignition has
been turned off.
Determine and eliminate the open circuit according to the wir
ing diagrams. Refer to Wiring diagrams, Troubleshooting &
Component locations.
103

5.1 Radiator, page 104

5.2 Coolant Pump, page 104
5.3 Coolant Thermostat, page 105
5.1
Radiator
e
wage
Spring Type Clip Pliers -VAS 5024 ARemoving

Remove the front bumper. Refer to Body Exterior; Rep. Gr.
63 ; Removal and Installation .
Disconnect the coolant hoses from the radiator.
Disconnect the harness connector from the thermal switch.
Bring the lock carrier into the service position. Refer to Body
Exterior; Rep. Gr. 50 ; Description and Operation .
Remove the bolts from the radiator and remove the radiator
with fans downward.
with Air Conditioning (A/C)
Installation is in the reverse order of removal, note the following:

AG.

Additional information and assembly work on vehicles with A/C

Caution
The A/C refrigerant circuit must not be opened.
Note
To prevent damage to the A/C condenser and also to the refrig

erant lines/hoses, ensure that the lines and hoses are not stretch
ed, kinked or bent.
Remove the retaining clamp(s) from the refrigerant lines.
Remove the A/C condenser from the radiator and secure it to
the lock carrier.
5.2
Coolant Pump
104
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Observe the additional information and removal work. Refer

to page 104 .
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Drip Tray -V.A.G 1306- or Drip
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Refractometer -T10007-
Drip Tray -V.A.G 1306- or Drip Tray for VAS 6100 -VAS 6208 Spring Type Clip Pliers -VAS 5024 ANote
Always replace gaskets and seals.

The lower part of the toothed belt cover can remain installed.
The toothed belt remains in position on the crankshaft sprock
et.
Cover the toothed belt with a cloth to protect it from coolant
before removing the coolant pump.
Removing
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Engine
Mechanical - Edition 07.2007
ss
Prote
cted
by
Remove the upper and lower sections of the toothed belt

guard. Refer to 5.1 Toothed Belt, page 60 .
Remove the toothed belt from the coolant pump toothed belt
gear. Refer to 5.1 Toothed Belt, page 60 .
Remove the coolant pump bolts -1- and remove the coolant
pump -2-.
Installing
Moisten the new O-ring with coolant.
Insert the coolant pump into the cylinder block and tighten the
bolts. Tightening specification: 15 Nm
Note
The coolant pump sealing plug faces downward.

Install the ribbed belt. Refer to 5.1 Ribbed Belt, page 36 .
5.3
Coolant Thermostat

Refractometer -T10007 Drip Tray -V.A.G 1306- or Drip Tray for VAS 6100 -VAS 6208 Torque Wrench (5-50 Nm) -V.A.G 1331 Spring Type Clip Pliers -VAS 5024 A-
105

Removing
Note
Always replace gaskets and seals.

Disconnect the coolant hose from the connecting piece -3-.
Remove the bolts -4- from the connecting piece -3- and re
move the connecting piece -3- with the thermostat -1-.
Installing
Moisten the new O-ring -2- with coolant.
Insert the thermostat -1- in the connecting piece -3- and turn
it 90 (1/4) to the right.
Insert the connecting piece -3- with thermostat -1- into the en
gine block.
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The clip of the thermostat must be positioned at approximately a

right angle.
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Tighten the bolts -4-. Tightening specification: 15 Nm
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106

07.2007
Special Tools
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EngineoeMechanical
- Edition
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Drip Tray for VAS 6100 -VAS 6208 Cooling System Charge Unit -VAS 6096 Voltage Tester -V.A.G 1527 B-
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Connector Test Set -V.A.G 1594 C-
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6. Special Tools
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Spring-Type Clip Pliers VAS 5024 A-
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Torque Wrench (5-50 Nm) V.A.G 1331-
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20
Fuel Supply
General Information
1.1 Safety Precautions, page 109

1.2 Clean Working Conditions, page 110
1.3 Fuel Supply System, page 110
1.4 Crash Fuel Shut-Off Function, page 110
1.5 Electronic Power Control System Function, page 111
1.6 Leak Diagnosis, Function, page 111
1.7 EVAP System, page 112
1.1
Safety Precautions
Caution

is followed.
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Always observe the following when removing and installing
the
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fuel level sensor or the fuel pump (fuel delivery unit)
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partially filled fuel tank:
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Before starting work, turn on the exhaust extraction system
and place an extraction hose close to the opening in the fuel
tank to extract escaping fuel fumes. If no exhaust extraction
system is available, a radial fan (as long as motor is not in air
flow) with a displacement greater than 15 m3/h can be used.
Prevent fuel from contacting skin! Wear fuel resistant gloves!
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For safety reasons, fuse No. 28 must be removed from the
fuse holder before opening the fuel system as the fuel pump
can be activated by the door contact switch in the driver's door.
1.2
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Clean Working Conditions
When working on the fuel supply/injection system, pay careful at

tention to the following 5 rules of cleanliness:
Thoroughly clean all connections and the surrounding area
before disconnecting.
Place parts that have been removed on a clean surface and
cover them using lint free cloths!
Carefully cover or seal opened components, if repairs are not
performed immediately.
Note
Hose connections are secured with either spring type or clamp
type clamps.
Always replace clamp type clamps with spring type clamps.

Fuel hoses at the engine must only be secured with spring type
clamps. The use of clamp or screw type clamps is not permis

sible.
Sporing type clip pliers -VAS 5024 A- or hose clip pliers -V.A.G
1.4
Crash Fuel Shut-Off Function
Vehicles with an airbag are equipped with a crash fuel shut-off

system. It reduces the danger of a fire in a crash as the fuel pump
is switched off via the fuel pump relay. At the same time, with this
set-up, an improvement in the comfort of engine startability is also
attained. When opening the door, the fuel pump is activated for 2
seconds to build pressure in the fuel system.
When opening fuel system:
Observe the safety precautions. Refer to
Check the fuel pump relay according to the wiring diagram
using the test system -V.A.G 1466 A- Wiring diagrams,
Troubleshooting & Component locations.
110
Rep. Gr.20 - Fuel Supply
AG.
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When the system is open: Avoid working with compressed air

if possible. Do not move the vehicle unless absolutely neces
sary.
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Only install clean components: Only unpack replacement

parts immediately prior to installation. Do not use parts that
have been stored loose (for example, in a tool box, etc.).

1.5
Electronic Power Control System Func

tion
For Electronic Power Control (EPC), the throttle valve is not op

erated by a cable from the accelerator pedal. There is no me
chanical connection between the gas pedal and the throttle valve.
The position of the accelerator pedal is transmitted to the Engine
Control Module (ECM) via two accelerator pedal position sensors
(adjustable resistances, accommodated in one housing), that are
connected to the accelerator pedal.
The position of the accelerator pedal (driver controlled) is a main
input for the ECM.
Operation of the throttle valve occurs via an electric motor (throttle
valve actuator) in the throttle valve control module. This applies
across the entire engine speed and engine load spectrum.
The throttle valve is operated by the throttle drive according to the
instructions of the ECM.
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With the engine at a standstill and the ignition turned on, the ECM
activates the throttle valve actuator precisely according
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specifications of the Throttle Position (TP) sensor.
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the accelerator pedal is pressed half way, rthe
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the throttle valve to the same degree; for
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With the engine running (under load) the ECM can open and close
the throttle valve independently of the accelerator pedal position
sensor.
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This means, for example, that the throttle valve could be fully
opened even though the accelerator pedal has only been pressed
half way. This has the advantage of preventing torque losses at
the throttle valve.
Aside from that, it results in clearly better pollutant output and
consumption values under certain load conditions.
The necessary engine torque can be produced by the ECM via
the optimal combination of throttle valve profile and charge pres
sure.
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Leak Diagnosis, Function
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1.6
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Observe rules for cleanliness. Refer to

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Observe safety precautions. Refer to

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It would be incorrect to think that EPC consists of only one or

two components. EPC is much more of a system containing all
components that contribute to recognizing, controlling and moni
toring the position of the throttle valve, for example, sensor for
accelerator pedal position, throttle valve control module, EPC
warning lamp, ECM.
The Evaporative Emission (EVAP) system (including fuel tank) is

equipped with leak diagnosis. The leak diagnosis will detect
whether the system is leaking.
The diagnosis operates by pressurizing the system and should
detect leaks where the damage exceeds 1 mm in diameter.
During the diagnostic, the leak detection pump -V144- generates
a positive pressure of approximately 30 mbar in the EVAP system.
The pump will switch off when the pressure is attained. When the
pressure falls to below a certain figure, the pump will switch on
again. On Board Diagnostic (OBD) monitors the switch intervals
111

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1.7
DTC memory
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and stores a Diagnostic Trouble

if the intervals are too short.
k
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Code (DTC)
ris in the
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Hose connections are secured with either spring type or clamp
type clamps.
Always replace clamp type clamps with spring type clamps.

Hose clip pliers -V.A.G 1921- or spring type clip pliers -VAS
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112
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5024 A- are recommended for installing spring clamps.

2.1 Fuel Tank and Attachments Overview, page 113 .

2.2 Electronic Engine Power Control Components Overview,
page 116
2.3 Meaning of Electronic Power Control Warning Lamp in In
strument Cluster, page 116
2.4 EVAP System Function, page 117
2.5 EVAP System Overview, page 118
2.6 EVAP System Routing Diagram, page 119
2.1
Fuel Tank and Attachments Overview
1 - Cap
2 - Seal
Replace if damaged.
3 - Bolt
4 - Tank Flap Unit
With a rubber gasket.
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5 - Vent Line
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Clipped in at the top
of
c
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s
the fuel tank.
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6 - Ground (GND) Connection

curely.
7 - Vent Line
White
curely.
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9 - Seal
Replace if damaged.
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8 - Gravity Valve
To remove the valve,
unclip upward out of the
support.
Check the valve for
through flow:
Valve vertical: open,
valve angled at 45:
Closed.
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10 - Switch-Over Valve
To remove the valve, unclip sideways out of the support.
Before installing, remove the cap -item 1-.
Checking, refer to Fig. Checking the Switch-Over Valve , page 115 .
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11 - Vent Line
Black
113

12 - Pressure Retention Valve
Checking, refer to Fig. Checking the Pressure Retaining Valve , page 116 .
13 - Vent Line
Black
14 - Fuel tank
Support using the engine-/gearbox jack -V.A.G 1383 A- when removing.
Removing and installing, refer to 5.3 Fuel Tank, page 144 .
15 - Lock Washer
16 - Heat Shield
For the fuel tank.
17 - Bolt
25 Nm
18 - Nut
2 Nm
19 - Fuel Tank Cover
20 - Securing Strap
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Installed location: Locating
point
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points
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the
driving
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22 - Fuel Filter
Installed location: The arrow points in the direction of flow.
23 - Screw Clamp
24 - Vent Line
White
Clipped to the side of the fuel tank.
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25 - Seal
Replace if damaged.
To install, place into the opening of the fuel tank dry.
Only coat with fuel when installing the fuel delivery unit flange.
rrectness of i
t to the co
nform
spec
a
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21 - Supply Line
c
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Black
To remove from the fuel filter, press the release buttons on the connecting piece.
To the fuel supply line at fuel rail, refer to Fuel Injection and Ignition; Rep. Gr. 24 ; Description and
Operation .
26 - Fuel Delivery Unit

Installation location on the fuel tank, refer to
Fig. Installed Position of the Fuel Delivery Unit Flange , page 115 .
Removing and installing, refer to 5.1 Fuel Delivery Unit, page 143 .
Fuel level sensor removing and installing, refer to 5.2 Fuel Level Sensor, page 144 .
Checking the fuel pump, refer to 4.1 Fuel Pump, Checking, page 121 .
Clean the strainer if dirty.
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27 - Lock Nut
75 Nm
Use the ring nut spanner -3217- for removal and installation.
114

28 - Supply Line
Black
To remove from the flange and fuel filter, press the release buttons on the connecting piece.
es, in part or in w
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29 - Return Line
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To remove from the flange, press the release buttons on the connecting piece.
From the fuel return line at fuel rail, refer to Fuel Injection and Ignition; Rep. Gr. 24 ; Description and
Operation .
31 - Bolt
10 Nm
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spec
atio
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30 - Connector
Black, 4-pin
For the fuel level sensor -G- and transfer fuel pump -G6- .
Installed Position of the Fuel Delivery Unit Flange

The mark on the sensor must align with the mark on the fuel tank
-arrows-.
Blue or blue marked return line -1- to the connection with identi
fication -R-.
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After installing the fuel pump flange, check whether the supply,
return and ventilation lines are still clipped in at the fuel tank.
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Black supply line -2- to connection with designation -V-.
Prote
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by
Checking the Switch-Over Valve

Lever in rest position: Closed
Lever pushed in the direction of the - arrow-: Open
Note
Before installing the switch-over valve, remove the cover from the
fuel tank.
115

Checking the Pressure Retaining Valve
The pressure retention valve is opened for flow in both directions
-arrow 1- by the Evaporative Emission (EVAP) canister and EVAP
canister purge regulator valve 1 -N80- .
It is only opened in one flow direction -arrow 2- on the side of
gravity valve.
2.2
Electronic Engine Power Control Components Overview
1 - Bracket
Removing and instal
ling, refer to Brake
System; Rep. Gr. 46 ;
Removal and Installa
tion .
2 - Connector
Black, 6-pin.
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2.3
Meaning of Electronic Power Control

Warning Lamp in Instrument Cluster
EPC is an abbreviation and stands for Electronic Power Control,

also known as electronic performance regulation.
116
do
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um
en
5 - Bracket
For the foot well cover.
Version through model
year 2001 is illustrated.
Clipped onto the sensor.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
4 - Accelerator Pedal Position

Sensor -G79- and Accelerator
Pedal Position Sensor 2 G185 Not adjustable.
The sensor transmits
driver control to the En
gine Control Module
(ECM).
To remove, remove the
instrument panel and
pedal assembly cover.
Checking, refer to
4.2 Accelerator Ped
al Position Sensor and
Accelerator Pedal Posi
tion Sensor 2, Check
ing, page 126 .
If replaced, adapt the
automatic transmission
control module.
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3 - Bolt
10
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Nm ss

After turning on the ignition, the Engine Control Module (ECM)
checks the function of all components used by the EPC system.
If malfunctions are detected in the EPC system during engine op
eration, the ECM switches on the EPC warning lamp. (These
Diagnostic Trouble Codes (DTCs) are identified in the DTC ta
bles). The malfunction is stored in the DTC memory of the ECM
at the same time.
EPC warning lamp location
2.4
EVAP System Function
Depending upon air pressure and ambient temperature - more or

less fuel vapors will form in the fuel tank.
The Evaporative Emission (EVAP) system prevents these Hy
drocarbon (HC) emissions from entering the atmosphere.
With quantity restrictions, fuel vapors travel from the highest point
of the tank via the gravity valve (closed G
at a tilt of 45) and the
A . Volkswagen AG d
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pressure retention valve to the lEVAP
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The pressure retention valve prevents fuel vapors from being

sucked out of the tank when the EVAP canister purge regulator
valve 1 is opened and an intake manifold vacuum is present. It
therefore ensures that the evacuation of the EVAP canister has
priority.
When no voltage is applied (for example, an open circuit), the
solenoid valve is closed. The EVAP canister is not purged.
The vacuum line from throttle valve control module to EVAP can
ister is also connected with crankcase ventilation valve via a
bypass. The check-valve integrated there prevents intake air from
entering the crankcase in certain partial throttle ranges. Thereby
the crankcase ventilation is altogether improved. The bypass en
sures crankcase ventilation.
rrectness of i
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When purging (recovery of the activated charcoal), the suction

tube vacuum sucks fresh air in through the ventilation opening on
the underside of the EVAP canister. The fuel vapors stored
amongst the activated charcoal and fresh air are proportionately
supplied to be burned.
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While driving, with oxygen
sensor control active (engine is warm),
the EVAP canister purge regulator valve 1 -N80- , is activated by
the Engine Control Module (ECM) in pulses dependent on load
and engine speed. The opening time is dependent on input sig
nals.
117
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Jetta 1999 , Jetta Wagon 1999 ,risGolf
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EVAP System Overview
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Note
Components marked with a * are checked via On Board Di
agnostic (OBD).
Components marked with a ** are checked via output Diag
nostic Test Mode (DTM).
1 - from the EVAP Canister

Purge Regulator Valve 1 -N80-
7 - Leak Detection Pump V144- */**

Under the right rear
wheel housing liner.
Checking, refer to
4.5 Leak Detection
Pump, Checking,
page 134 .
8 - Connecting Hose
Pressure side.
9 - Screw
3 Nm
10 - Air Filter for the Leak De
tection Pump
11 - Connecting Hose
Suction side.
12 - Bracket
13 - Bolt
10 Nm
14 - EVAP Canister
Under the right rear wheel housing liner
118
Prote
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6 - Vacuum Line
To the throttle valve
control module.
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5 - Connector
3-pin
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3 - Vent Line
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2 - Seal
Replace if damaged.
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*/**

2.6
EVAP System Routing Diagram
1 - Tank Flap Unit

2 - Fuel Tank
3 - Fuel Delivery Unit
4 - Intake Tube
5 - Throttle Valve Control Mod
ule -J3386 - Intake Manifold
7 - Fuel Rail with Injectors
8 - Fuel Pressure Regulator
13 - Pressure Retention Valve

14 - Switch-Over Valve
15 - EVAP Canister
Under the right rear
16 - Leak Detection Pump -V144 Check the activation.
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17 - Air Filter for the Leak Detection Pump
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11 - Test Connection
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10 - EVAP Canister Purge

Regulator Valve 1 -N80 Check the activation.
Function, checking, re
fer to
4.3 Evaporative
Emission Canister
Purge Regulator Valve,
Checking, page 129 .
un
le
9 - Fuel Filter
Installed location: The
arrow points in the direc
tion of flow.
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119
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Specifications
Components
Nm
25
25
2
75
10
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120
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Heat shield for fuel tank

Securing strap
Cover to securing strap nut
Fuel delivery unit lock ring
Fuel tank
Air filter for Leak detection pump -V144-
Bolt Size
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3.1

4.1 Fuel Pump, Checking, page 121

4.2 Accelerator Pedal Position Sensor and Accelerator Pedal
Position Sensor 2, Checking, page 126
4.3 Evaporative Emission Canister Purge Regulator Valve,
Checking, page 129
4.4 EVAP System, Checking for Leaks, page 131
4.5 Leak Detection Pump, Checking, page 134
4.6 EVAP System, Checking with Tester KLI 9210,
page 136
4.1
Fuel Pump, Checking
4.1.1 Function and Voltage Supply, Checking, page 122

4.1.2 Delivery Rate, Checking, page 123
4.1.3 Fuel Pump Check Valve, Checking, page 125
Ring Nut Spanner -3217Volkswa
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-V.A.G 1318/1-
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Fuel Line Feed Adapter -V.A.G 1318/23 Torque Wrench (40-200 Nm) -V.A.G 1332-
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Pressure Gauge Adapter -V.A.G 1318/17-
Injection Rate Comparison Meter -V.A.G 1348 Test System -V.A.G 1466 A Voltage Tester -V.A.G 1527 B Connector Test Set -V.A.G 1594 A- or -V.A.G 1594 C Multi-meter -V.A.G 1715 Measuring Container
Wiring Diagram
Test Conditions
Fuse No. 28 is OK
Battery voltage must be at least 11.5 volts.
All electrical consumers such as, for example, lights and rear
window defogger, must be turned off.
If the vehicle is equipped with Air Conditioning (A/C), it must

be turned off.
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Note
Observe the description of the crash fuel shut-off function. Refer

to 1.4 Crash Fuel Shut-Off Function, page 110 .
121
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Function and Voltage Supply, Checking
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4.1.1
In the continuing work procedure, it is possibly necessary to dis

connect the battery Ground (GND) cable. Check whether a coded
radio is installed. If so, obtain the anti-theft code beforehand.
Remove the cover from fuel delivery unit.
If fuel pump does not activate:
Remove the cover from the front fuse holder.
Connect the remote control -V.A.G 1348/3A- with the adapter

cable -V.A.G 1348/3-2- to the contact 28a to fuel pump and
battery positive (+).
If the fuel pump is not activated:

Disconnect the 4-pin connector from the flange at the fuel de
livery unit.
Connect the voltage tester -V.A.G 1527 B- using adapter ca
bles from the connector test set -V.A.G 1594C- to the outer
terminals of the connector.
Operate the remote control. The Light Emitting Diode (LED)
must light up.
Locate and repair the open circuit in the wiring using the wiring
diagram. Refer to Wiring diagrams, Troubleshooting & Com
ponent locations.
If the LED lights up (the voltage supply is OK):
Use the ring nut spanner -3217- to remove the lock nut.
Check if the electrical wiring between the flange and fuel pump
is connected.
If no open circuits are found:
The fuel pump is faulty, replace the fuel delivery unit. Refer to
5.1 Fuel Delivery Unit, page 143 .
122
AG.
Check the fuel pump relay according to the wiring diagram

using the test system -V.A.G 1466 A- . Refer to Wiring dia
grams, Troubleshooting & Component locations.
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If the fuel pump is activated:
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Operate the remote control -V.A.G 1348/3A- .
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Pull fuse No. 28 from the fuse holder.
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Turn off the ignition.
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Briefly operate the starter. The fuel pump must run audibly.

4.1.2
Delivery Rate, Checking
Test Conditions
The voltage supply is OK.
The remote control -V.A.G 1348/3A- is connected.
Test Sequence
Remove the fuel filler cap from the fuel filler tube.
WARNING

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Connect the fuel inj. pressure gauge-CIS -V.A.G 1318- with

the fuel line feed adapter -V.A.G 1318/23- and the pressure
gauge adapter -V.A.G 1318/17- to the fuel supply line.
Connect the pressure gauge adapter -V.A.G 1318/1- to the
adapter -V.A.G 1318/11- on the fuel inj. pressure gauge-CIS
-V.A.G 1318- and hold it in a measuring container.
Open the shut-off lever on the fuel inj. pressure gauge-CIS V.A.G 1318- . The lever will point in the direction of flow -A-.
Operate the remote control -V.A.G 1348/3A- . Slowly close the
shut-off lever, until the pressure gauge shows 3 bar. From this
point on do not move the position of the shut-off lever.
Empty the measuring container.
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Operate the remote control for 30 seconds and measure the

battery voltage.
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The delivery rate of the fuel pump is dependent on battery

voltage. Therefore, connect a multi-meter to the vehicles bat
tery using adapter cables from the connector test set -V.A.G
1594 C- .
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Disconnect the fuel supply line -1- and catch any leaking fuel
using a cloth.
123
Prote
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Compare the quantity of fuel delivered with the specification.
*) Minimum delivery rate cm3/30 s
**) Voltage at fuel pump with engine off and pump running (ap
proximately 2 volts less than battery voltage).
Example
During the test, a voltage of 12.5 volts is measured at the battery.
Since voltage at the pump is approximately 2 volts less than bat
tery voltage, there is a minimum delivery rate of 200 cm3/30 s.
If the minimum delivery rate is not attained
Check the fuel lines for possible restrictions (kinks) or block
ages.
WARNING

Disconnect the supply line -1- from the inlet on the fuel filter.
Connect the fuel inj. pressure gauge-CIS -V.A.G 1318- with
the adapter -V.A.G 1318/17- to the fuel supply line.
Repeat the delivery rate check.
If the minimum delivery rate is now obtained
Replace the fuel filter:
If the minimum delivery rate is again not obtained
AG. Volkswagen A
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Only when up to now no malfunction
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(ECM) was disconnected from the voltage supply, the readi
ness code must be regenerated.
If the delivery rate has been obtained, but malfunctions are still
suspected in the fuel supply, for example sporadic loss of fuel
supply:
Check the current draw of the fuel pump as follows:
Reconnect all disconnected fuel lines.
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124
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The fuel pump is faulty, replace
fuel delivery unit. Refer to

Connect the multi-meter -V.A.G 1715- with a current clamp to
wire for the 4-pin connector terminal 1 -arrow- on the wiring
harness.
Start the engine and run at idle speed.
Measure the current draw of the fuel pump. Specified value:
Max. 8 amps.
Note
If the malfunction in the fuel system is sporadic, the test can also
be performed during a road test, but a second person is required.
If the current draw is exceeded:
The fuel pump is faulty, replace fuel delivery unit. Refer to
If the DTC memory was cleared or the ECM was disconnected
from the voltage supply, the readiness code must be regen
erated.
n AG. Volkswagen A
Fuel Pump Check Valve, Checking

ss
The remote control -V.A.G 1348/3A- is connected.
The fuel inj. pressure gauge-CIS -V.A.G 1318- is still connec

ted.
Note
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Test Sequence
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Test Conditions
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4.1.3
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This test also checks the connections of the fuel supply line from
fuel delivery unit to the connection point of the fuel inj. pressure
gauge-CIS -V.A.G 1318- for proper sealing.
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125
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Close the fuel inj. pressure gauge-CIS -V.A.G 1318- shut-off
lever (lever is at right angle to the direction of flow position
-B-).
Operate the remote control at short intervals, until a pressure
of approximately 3 bar has built up.
WARNING
Danger of spraying when opening the shut-off lever; wear pro

lkswagen AG
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Watch the pressure drop on the gauge. After 10 minutes the

pressure must not drop below a 2.5 bar decrease.
If the pressure drops further:
Check the line connections for leaks.

If no fault is detected in the wiring:
The fuel pump is faulty, replace fuel delivery unit. Refer to

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Accelerator Pedal Position Sensor and

Accelerator Pedal Position Sensor 2,
Checking
Connector Test Set -V.A.G 1594 A- or -V.A.G 1594 C Adapter Cable (121-pin) -V.A.G 1598/31 Fault Read Out Device -V.A.G 1551- or Vehicle Diagnosis,
Testing and Information System -VAS 5051 Wiring Diagram
Function
The accelerator pedal position sensor -G79- and accelerator ped
al position sensor 2 -G185- are located on the accelerator pedal
and transmit the driver's intentions to the Engine Control Module
(ECM) completely independent of one another. Both sensors are
integrated into one housing.
126
AG.
Multi-meter -V.A.G 1526 A- or -V.A.G 1526 C-
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4.2
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If pressure builds up too high, lower the excess pressure by

carefully opening the shut-off lever.

Test Conditions
The fuses must be OK.
Test Sequence
engine electronics control module with Address word 01. For
this, the ignition is turned on. Connect the fault read out device
and select ECM.
Scan tool display:
Select function XX
Press buttons 0 and 8 for function eReading

value
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Scan tool display: (14 = display fields)

Read measured value block 62 ->
1 2 3 4
Check the specified value of the accelerator pedal position

sensor at idle stop in display field 3.
Specified value: 6 to 96%
Check the specified value of the accelerator pedal position
sensor 2 at idle stop in display field 4.
Specified value: 3 to 48%
Note
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Slowly press the accelerator pedal to the Wide Open Throttle

(WOT) position, when doing so, observe the percentage dis
play in display fields 3 and 4:
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The ECM converts the angle sensor voltage values based on 5

volts and shows these in percentage values. (5 volt voltage supply
corresponds to 100%).
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Read measuring value sblock
Scan tool display:
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The percentage displays in display field 3 must increase evenly.

Specified range 6 to 96% is not completely utilized during this.
The percentage displays in display field 4 must increase evenly.
Specified range 3 to 48% is not completely utilized during this.
Note
Displayed value in display field 3 must always be approximately

twice as large as value in display field 4.
Press key.
127

If the readings do not result as described:
Check the voltage supply and sensor wiring connections:
Voltage supply and wiring to control module, checking
Remove the drivers side storage compartment. Refer to
Body Interior; Rep. Gr. 68 ; Description and Operation .
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Disconnect the 6-pin connector from
accelerator
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Turn the ignition on.
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Terminal 1 + Ground
Terminal 1 + 5
Terminal 2 + Ground
Terminal 2 + 3
Specified value: at least 4.5 V

Turn the ignition off .
If no voltage is present:
AG.
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128
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Connect the adapter cable, (121-pin) -V.A.G 1598/31- to the

ECM wiring harness. The ECM remains disconnected.
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Connect the multi-meter for voltage measurement to the fol

lowing connector terminals with adapter cables from the con
nector test set -V.A.G 1594 C- .
or
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Check the wires between the adapter cable, (121-pin) -V.A.G
1598/31- and connector for open circuit according to the wiring
diagram.
Terminal 1 + socket 72
Wiring resistance: Max. 1.5
Also check the wires for short circuit to B+ or Ground.
Also check the wires for short circuit to each other.
If no malfunction is detected in the wiring:
Replace the accelerator pedal position sensor.
Adapt the automatic transmission control module.
Volkswagen AG
If the DTC memory was cleared or the ECM
was
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The solenoid valve is closed when no voltage is present.

Check activation.
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Testing and Information System -VAS 5051-
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Evaporative Emission Canister Purge

Regulator Valve, Checking
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Test Conditions
The coolant temperature must be at least 80 C (176 F)

Display group 04, display field 3
Fuse no. 43 must be OK.
Functional Test
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Connect the fault read out device
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engine must run at idle
o
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c
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Select function XX
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Press buttons 0 and 8 for function Reading measuring value

blocks and press Q button to confirm input.
Scan tool display:
Read measuring value block


1 2 3 4
Press button 4 for Basic Setting function (Tank ventilation

valve diagnosis is initiated)
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During this diagnosis, engine load must not be generated or di

agnosis will be terminated and can only be re-initiated after press
ing the accelerator pedal.
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1 2 3 4
If the diagnosis is initiated by the ECM, the display in display field

4 goes from Test OFF to Test ON.
Allow the engine to continue running at idle until specified val
ue TEV OK is shown in display field 4.
Note
TEV means (tank ventilation valve) (solenoid valve 1 for EVAP

canister)
If TEV not OK is shown in display field 4:
Initiate the diagnostic test mode (DTM) and activate the EVAP
canister purge regulator valve 1 -N80- .
130
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Scan tool display:

erated.
If the specified value TEV OK is reached:
Press the key.
Scan tool display:
Select function XX

4.4
EVAP System, Checking for Leaks

Testing and Information System -VAS 5051-
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Test Conditions
No Diagnostic Trouble Codes (DTCs) in the DTC memory.
All electrical consumers such as, for example, lights and rear
window defogger, must be turned off.
If the vehicle is equipped with Air Conditioning (A/C), it must

be turned off.
Throttle valve angle less than 10 Display group 03, display

field 3.
Coolant temperature less than 99 C (210 F) Display group

04, display field 3.
Intake air temperature less than 95 C (203 F) Display

group 04, display field 4
Functional Test
Connect the fault read out device -V.A.G 1551- and select en
gine electronics control module with Address word 01. The
engine must run at idle for this. Connect the fault read out de
vice and select Engine Control Module (ECM).
Scan tool display:
Select function XX

Scan tool display:

Reed open Test OFF
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Press buttons 0 7 and 1 for Display group

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Scan tool display

Reed open Test ON
Scan tool display

Reed closed Test ON
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Press button 4 for Initiate basic setting function
The Evaporative Emission (EVAP) system test is initiated. First,

function of the reed contact (in the leak detection pump -V144- )
is checked by the control module.
After approximately 10 seconds, the leak detection pump is acti

vated and generates pressure in the fuel system.
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132
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Reed closed Syst. Test Test ON
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Scan tool display

Scan tool display
Reed open Syst. Test Test ON
After approximately 50 seconds, the test is initiated (this can take

up to 120 seconds if there is insufficient pressure in the fuel sys
tem).
Scan tool display
Reed open Measurement Test ON
The leak detection pump switches off and the time until the reed
contact closes is measured by the control module.
Scan tool display
Reed closed END of measurement Syst. OK
Check the display in display fields 3 and 4:

Display field 3 specified value: END of measurement
Display field 4 specified value: Syst. OK
Check for leaks. Refer to page 133 .
If the specified values are achieved:
Press key.
Checking for Leaks
If a small or large leak was recognized during the EVAP system
functional test, proceed as follows.
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Check whether the fuel filler cap is completely
closed
or wheth
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If the malfunction persists:
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Repeat the functional test.
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Fold the rear seat bench forward.
Remove the cover under the bench seat.

Check whether the fuel delivery unit lock nut is tight or the seal
is faulty, replace as necessary. Tighten the lock nut using the
ring nut spanner -3217- . Check the supply and return lines to
fuel delivery unit for leaks.
Remove the right rear wheel housing liner. Refer to Body

Check the pressure hose between the leak detection pump
and EVAP canister for leaks, replace as necessary.
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Check the lines and line connections between the EVAP can
ister and tank flap unit or tank ventilation valve for leaks. Refer
to 2.6 EVAP System Routing Diagram, page 119 .
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133
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Remove the EVAP canister and check for tears and leaks, re
place if necessary.
4.5
Leak Detection Pump,

Checking
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4.5.1 Diagnostic Pump,yChecking
Electrically, page 134
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4.5.2 Voltage Supply,
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Multi-meter -V.A.G 1526 A- or -V.A.G 1526 C Connector Test Set -V.A.G 1594 A- or -V.A.G 1594 C Adapter Cable, (121-Pin) -V.A.G 1598/31 Wiring diagram
Disconnect the 3-pin connector from the leak detection pump
-V144- .
Connect the multi-meter for resistance measurement between
terminals 1 and 3 of the leak detection pump. Specified value:
640 to 720 .
Connect the multi-meter for resistance measurement between
terminals 2 and 3 of the leak detection pump. Specified value:
12.5 to 19.5.
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Replace the leak detection pump.
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If specifications are not obtained:

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4.5.2
Voltage Supply, Checking

Multi-meter -V.A.G 1526 A- or -V.A.G 1526 C Voltage Tester -V.A.G 1527 B Connector Test Set -V.A.G 1594 A- or -V.A.G 1594 C Adapter Cable, (121-Pin) -V.A.G 1598/31 Wiring Diagram
134
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Voltage Tester -V.A.G 1527 B-
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Diagnostic Pump, Checking Electrically
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4.5.1
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Test Conditions

Disconnect the 3-pin connector from the leak detection pump

-V144- .
Connect the voltage tester -V.A.G 1527 B- between terminal
3 (positive) on the connector and Ground (GND).
Start the engine and run at idle speed: The Light Emitting Di
ode (LED) must light up.
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If the LED lights up (the voltage supply is OK):
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Check the wire between terminal 3 on the connector and the

central electronics for a open circuit according to the wiring
diagram. Wiring resistance: Max. 1.5
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Test Sequence
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Engine Control Module (ECM) wiring harness. The ECM re
mains disconnected.
135
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Check the wiring between the adapter
cable,
(121-pin)
-V.A.G
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Engine Mechanical - Edition 07.2007sed
1598/31- and 3-pin connector for a open circuit according to

the wiring diagram.
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Also check the wires for short circuits to each other. Specified
value:
If no malfunction is found in the wires and there was voltage be
tween terminal 3 and Ground (GND):
Replace the leak detection pump.

EVAP System, Checking with Tester

KLI 9210
4.6.3 Fuel Cap, Testing, page 137

4.6.4 Leak Detection Pump V144, Checking for Internal
Leaks, page 137
4.6.5 Conditions, page 138
4.6.6 EVAP System, Checking for Leaks, page 141
4.6.1
Introduction
The -KLI 90210- Evaporative Emission (EVAP) tester allows test

ing using nitrogen to pressurize the EVAP system and a smoke
generator or ultrasonic tester to locate the source of EVAP system
concerns.
This procedure is intended as a general guide for the use of the
EVAP tester. EVAP systems vary between models.
-VAS 5051- or -VAS 5052- diagnostic tester
-KLI 90210- EVAP system tester (set to 14 in. H2O)
Light source (for viewing smoke)
Hose Clamps up to 25 mm dia. -3094- or equivalent
Using the -KLI 90210- EVAP system tester Tester operating
instructions
4.6.2
KLI 90210 Tester, Calibrating
Determine the vehicle leak threshold:

Up to and including Model Year (MY) 1999 leak threshold =
0.040 in.
From MY 2000 leak threshold = 0.020 in.
136
AG.
4.6.2 KLI 90210 Tester, Calibrating, page 136
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4.6.1 Introduction, page 136
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Attach test hose to the appropriate preset port

-black arrows-.
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Turn the control valve from Hold to Test.

Set the flow meter flag -white arrow- at the indicated value on
the flow meter.
Turn the control valve to Hold; remove the test hose.
4.6.3
Fuel Cap, Testing
Remove the fuel cap.
Screw the fuel cap tightly to the cap receiver.
AG.
Watch the pressure gauge for a drop in pressure from 14 in

ches H2O.
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Turn the valve to Hold.
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Turn the control valve to Test pressurizing the cap.
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Connect the fuel cap receiver -arrow- to the hose.
If no pressure drop is indicated:

Proceed to checking the leak detection pump -V144- for inter
nal leaks.
If a pressure drop is indicated:
Replace the fuel cap and retest.
Proceed to checking the leak detection pump for internal
leaks.
4.6.4
Leak Detection Pump V144, Checking

for Internal Leaks
Basically, in the following procedure the EVAP system will be fil

led with smoke, the engine started and the leak detection pump
activated using the -VAS 5051- or -VAS 5052- . With the leak
detection pump activated, and after clearing the initial smoke
away from the leak detection pump area using compressed air,
the system is then filled with smoke again and rechecked for
smoke at the leak detection pump filter.
137

4.6.5
-VAS 5051- or -VAS 5052- Diagnostic tool connected to the

vehicle
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Tester hose connected to the fuel fillerautneck
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The ignition is turned off
Smoke generator connected to the battery

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Conditions
Start the engine.
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s
Turn the -KLI 90210- valve to Test and use the smoke gen
erator trigger to fill the system with smoke (wait until smoke is
coming out of the leak detection pump filter).
From the -VAS 5051- Start-up screen, select Vehicle self di
agnosis.
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Select the diagnosis function 04 - Basic settings.
Input the appropriate display group from the table below on

keypad.
Engine code
Display group
AEB, AEG, AFP, AHA, APH, ATQ, ATW, AUG, AWD,

AWM, AWP, AWV, AWW, BDC, BDF, BEV, BGD, BGJ
071
138
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Select the vehicle system 01 - Engine electronics.

Engine code
Display group
AVH, AZG, BAP, BBW, BDP
202
Press Q on keypad to confirm.

The leak detection pump should activate
If the leak detection pump does not activate:
For some vehicles using Display group 202 a similar screen ap
pears indicating Test Off.
Select Activating button.
If the leak detection pump does not activate:
Check the electrical connections to the leak detection pump.
Check the vacuum source to the leak detection pump.
If the leak detection pump activates:
rrectness of i
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A similar screen appears, Test is ON(indicated by

tion 5, -arrow-).
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Position 1 -arrow- alternates between 0 and 1 during pump

operation.
139
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If the test is OK:
Indicated by 1 in position 6 and a 0 in position 8 as shown.
The leak detection pump has activated and the system is pres
surized.
Using a compressed air blow gun, clear the area near the leak
detection pump and leak detection pump filter of any residual
smoke.
If the test aborts and Diagnostic Trouble Codes (DTCs) other than
for small or large leaks are stored:
Check and repair according to the DTC listed in the DTC table
for the appropriate engine code.
When Check end is indicated on the -VAS 5051- or -VAS 5052- :
Note
Only check the leak detection

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Use the smoke
generator
ho
ut
again. ss a
Check for smoke coming from the leak detection pump filter
and leak detection pump hose connections.
Smoke coming from the leak detection pump outlet or hose

indicates a faulty hose or clamp
Make repairs as necessary and check with smoke again.
No smoke coming from the filter indicates the leak detection
pump is OK and the leak is somewhere else in the EVAP sys
tem
Note
If the leak detection pump is OK and a DTC was stored for the
EVAP system:
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Continue checking the EVAP system as follows:
AG.
140
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Turn the ignition off.
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If the -KLI 90210- EVAP system tester is connected in Test

mode and Basic settings (using Self Diagnosis) and Fault finding
are activated, a false System OK message may be generated.
rrectness of i
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spec
atio
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wit
Smoke coming from the filter indicates a faulty leak detection

pump

4.6.6
EVAP System, Checking for Leaks
Clamp off the leak detection pump outlet (EVAP side) -1- using
a hose clamp up to 25 mm dia. -3094- or equivalent.
WARNING
Clamp only the soft rubber hoses when isolating a leak. To

avoid risk of damage, never clamp hard plastic lines!
Turn the control valve from Hold to Test.
Allow the fuel system to pressurize.
Note
The fuel system pressurization depends on the volume of the fuel

system and amount of fuel in tank.
If the fuel system pressurization does not stabilize:
Verify that all fuel system outlets have been sealed before
continuing.
Note
Any flow shown on the flow meter indicates a leak. Flow below
the flow meter flag set at vehicle leak standard may indicate a
sporadic Diagnostic Trouble Code (DTC).
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If the flow meter on the tester registers
preset pressure:
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If the flow stops:
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Clamp off the hose leading from the EVAP canister purge reg
ulator valve 1 -N80- to the intake manifold.
rrectness of i
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a
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Replace the EVAP canister purge regulator valve 1 and repeat

the test before continuing.
If the meter indicates no flow after the test:
Perform a quality check and return the vehicle to the customer.
If the flow continues:
Use the smoke generator trigger to charge the fuel system with
smoke again.
Note
It may be necessary to move, twist, or wiggle EVAP components

around to reproduce the leak.
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If the leak cannot be found using smoke:
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Inspect the complete EVAP system for escaping smoke.
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141
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Locate the leak using an ultrasonic tester.
General the search: tester only
Localized search: tester with extension wand (left)
If the leak cannot be located:
Disconnect and plug or clamp the shut EVAP lines to isolate
the fuel tank using a hose clamp up to 25 mm dia. -3094- or
equivalent before continuing.
WARNING
Clamp only the soft rubber hoses when isolating a leak. To

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If the flow stops:
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When the leak has been located:
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Reconnect the EVAP lines and search area that was isolated.
rrectness of i
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a
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Note
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Repair the leak and repeat EVAP system test.
Because the leak may be at the top of the fuel tank, it may not
be possible to locate through fuel pump/sending unit access

plate.
Lower the fuel tank if necessary to locate the leak.

WARNING
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142
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Do not return the vehicle to the customer without having per

formed a proper diagnosis and repair.


G. Volkswagen
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5.1 Fuel Delivery Unit, page 143
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5.2 Fuel Level Sensor,hpage
144
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Fuel Delivery Unit
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Ring Nut Spanner -3217 Torque Wrench (40-200 Nm) -V.A.G 1332Removing

anti-theft code.
(GND) cable.
Remove the cover under the rear bench seat.
Disconnect the 4-pin connector and the supply and return lines
from the flange.
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5.3 Fuel Tank, pagess 144
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WARNING
The fuel supply lines are under pressure! Wear protective gog
gles and protective clothing to prevent injuries and contact with
skin. Before removing from hose connection wrap a cloth
around the connection. Then release pressure by carefully
pulling the hose off the connection.
Use the ring nut spanner -3217- to remove the lock nut.
Pull the fuel delivery unit and seal out of the fuel tank opening.
Note
If the delivery unit is to be replaced then drain the old delivery unit
before disposal.
Installing
Installation of the fuel delivery unit is in the reverse order of
removal.
143

Note
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fuel level sensor.
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When inserting the fuel delivery
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Insert the dry flange seal into the opening of the fuel tank.
Only coat the seal with fuel when installing the fuel delivery
rrectness of i
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unit.
Ensure the fuel hoses are seated securely.

Note the installed position of the fuel delivery unit flange: The
mark on the flange must align with the mark on the fuel tank
-arrows-.
After installing the fuel delivery unit, check that the supply, re
turn and ventilation lines are still clipped onto the fuel tank.

and Testing .
Fuel Level Sensor
Remove the fuel delivery unit. Refer to

Installing
Insert the fuel level sensor into the guides on the fuel delivery
unit and push it up until it engages.
Install the fuel delivery unit. Refer to
5.3
Fuel Tank

Torque Wrench (40-200 Nm) -V.A.G 1331 Engine-/Gearbox Jack -V.A.G 1383 ARemoving
anti-theft code.
(GND) cable.
Open the fuel tank flap.
Remove the rear subframe. Refer to Suspension, Wheels,
Steering; Rep. Gr. 42 ; Removal and Installation .
144
AG.
Pry up the retaining tabs -1 and 2- using a screwdriver and

remove the fuel level sensor towards the bottom -arrows-.
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Disengage the connector prongs for the wires -3 and 4- and

disconnect.
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Removing
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5.2

Drain the fuel tank and clean the fuel filler tube and surround
ing area.
Remove the bolt and remove the fuel flap unit with rubber
gasket.
Remove the bolt for the filler neck.
Fold the rear seat bench forward.
Remove the cover plate from the fuel level sensor and dis
connect the connector.
Remove the covers under the fuel tank.
WARNING
The fuel supply lines are under pressure! Wear protective gog
gles and protective clothing to prevent injuries and contact with
skin. Before removing from hose connection wrap a cloth
around the connection. Then release pressure by carefully
pulling the hose off the connection.
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Disconnect the return line -2- (blue),
line -1- (black) and
Vsupply
by connection points.
ventilation line -3- (white) fromistheir
ed
un
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Remove the tensioning strap. While doing so, support the fuel
tank using the engine-/gearbox jack -V.A.G 1383 A Lower the fuel tank.
Installing

Make sure the ventilation and fuel lines are not kinked when
installed.
Route the fuel lines free of kinks.
Ensure the fuel lines are seated securely.
Secure the fuel hoses with spring type clamps.
After installing the fuel tank, check that the supply, return and
ventilation lines are still clipped onto the fuel tank.
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Do not interchange the supply and return lines (the return line
is blue or has blue marks, the supply line is black).
rrectne
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Squeeze the buttons together on the line connections to do this.
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Note
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AG.

and Testing .
145

Special Tools

Adapter Cable, (121-pin) -V.A.G 1598/31-
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146
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Engine-/Gearbox Jack -V.A.G 1383 A-

Ring Nut Spanner -3217 Fuel Inj. Pressure GaugeCIS -V.A.G 1318 Pressure Gauge Adapter V.A.G 1318/1 Adapter -V.A.G 1318/11 Pressure Gauge Adapter V.A.G 1318/17-
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Fuel Line Feed Adapter V.A.G 1318/23-
6. Special Tools
147
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Torque Wrench (40-200
Nm) -V.A.G 1332 Injection Rate Comparison
Meter -V.A.G 1348-
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148
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Multi-meter -V.A.G 1715- or

-V.A.G 1526 C-
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Connector Test Set -V.A.G

1594 A- or -V.A.G 1594 C-
un
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Voltage Tester -V.A.G 1527

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Test System -V.A.G 1466

A-

21
Turbocharger, Supercharger
General Information
1.1 Safety Precautions, page 149

1.2 Clean Working Conditions, page 149
1.3 Charge Air System with Turbocharger, page 150
olkswagen AG
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Safetyy VPrecautions
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Caution
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1.1

rrectness of i
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spec
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wit

orative Emission (EVAP) system, coolant, refrigerant,
brake fluid and vacuum) and electrical wiring so that the
original path is followed.
Ensure sufficient clearance to all moving or hot compo
nents.
WARNING
Observe the following if test and measuring instruments are

required during a test drive:
If test and measuring instruments are operated from the front

passengers seat and the vehicle is involved in an accident,
there is a possibility that the person sitting in this seat may
receive serious injuries when the airbag is triggered.
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Clean Working Conditions

AG.
1.2
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Test and measuring instruments must be secured to rear

seat and operated by a 2nd person from this location.
When working on the turbocharger, carefully observe the follow

ing 5 rules of cleanliness:
Thoroughly clean all connections and surrounding area before
disconnecting.
Place parts that have been removed on a clean surface and
cover them using lint free cloths!
Carefully cover or seal, opened components if repairs are not
performed immediately.
Only install clean components: Only unpack replacement
parts immediately prior to installation. Do not use parts that
have been stored loose (for example in a tool box, etc.).
When the system is open: Avoid working with compressed air
if possible. Do not move the vehicle unless absolutely neces
sary.
149

1.3
Charge Air System with Turbocharger

Note
Various hose connections are secured with clamps.

The charge air system must be properly sealed.
Replace self-locking nuts.
Vacuum hoses and connectors must be free of grease when
reinstalling.
Spring type clip pliers -VAS 5024 A- or hose clip pliers -V.A.G
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Rep. Gr.21 - Turbocharger, Supercharger
thi
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150
rrectness of i
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2.1 Turbocharger with Attachments Overview, page 151

2.2 Charge Air Cooler Components Overview, page 155
Engine Code AWD
2.3 Exhaust Turbocharger System Overview, page 157
Engine Codes AWP and AWW
2.4 Exhaust Turbocharger System Overview, page 158
2.1
Turbocharger with Attachments Over

view
2.1.1 Part I, page 151

2.1.2 Part II, page 153
Part I
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2.1.1
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1 - Nut
40 Nm
Coat the threads with
hot bolt paste -G 052
112 A3- .
2 - Seal
Always replace.
3 - Bolt
10 Nm
Must not be loosened.
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4 - Vacuum Diaphragm
For the boost pressure
regulator valve.
Can only be replaced to
gether with the turbo
charger.
Charge pressure regu
lation, checking. Refer
to
4.1 Boost Pressure
Regulation, Checking,
page 161 .
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5 - Clip
6 - Turbocharger
Charge pressure regu
lation, checking. Refer
to
4.1 Boost Pressure
Regulation, Checking,
page 161 .
The boost pressure reg
ulator valve and vacuum
diaphragm for boost
pressure regulator valve
are part of the exhaust turbocharger and cannot be replaced individually.
Before connecting the oil supply line, fill the turbocharger with oil at the line connection.
After installing the turbocharger, let the engine idle for approximately 1 minute without increasing the
engine speed. This ensures adequate oil supply to the turbocharger.
151

7 - O-ring
Always replace.
8 - Bolt
10 Nm
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9 - Intake Manifold
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11 - Bolt
20 Nm
12 - Heat Shield
13 - Bolt
10 Nm
14 - Banjo Bolt
30 Nm
15 - Oil Supply Line
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10 - Gasket
Always replace.
AG.
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18 - Gasket
Always replace.
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17 - Exhaust Manifold
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16 - Bolt
30 Nm
Always replace.
Coat the threads and bolt head contact surfaces with hot bolt paste -G 052 112 A3- (Part numbers are
for reference only. Always check with your Parts Department for the latest part number information).
19 - Bolt
20 Nm
20 - Banjo Bolt
30 Nm
21 - Nut
25 Nm
Always replace.
Coat the threads with hot bolt paste -G 052 112 A3- (Part numbers are for reference only. Always check
with your Parts Department for the latest part number information).
22 - Banjo Bolt
35 Nm
23 - Coolant Return Line
24 - Bolt
25 Nm
25 - Spacer Sleeve
26 - Banjo Bolt
35 Nm
27 - Bolt
10 Nm
152

28 - Coolant Supply Line
29 - Banjo Bolt
35 Nm
30 - Bolt
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Only
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32 - Bolt
25 Nm
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31 - Bracket
Between the turbocharger and cylinder block.
33 - Gasket
Always replace.
34 - Gasket
Always replace.
35 - Bolt
10 Nm
36 - Oil Return Line
To the oil pan.
37 - Bolt
10 Nm
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2.1.2
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38 - Nut
10 Nm
Do not change the adjustment.
Must not be loosened.
Part II
Note
agnostic (OBD).
Components marked with a ** are checked via output Diag
nostic Test Mode (DTM).
Note the installed position of the heat shield mats
153

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8 - Bracket
9 - Bolt
40 Nm
10 - Bolt
25 Nm
11 - to the Connection Hose for the Lower Connection Sleeve/Charge Air Cooler
12 - O-ring
Always replace.
13 - Retaining Clip
14 - Bolt
10 Nm
15 - from the Turbocharger Exhaust Connection
To the vacuum diaphragm for boost pressure regulator valve.
18 - Retaining Clip
154
do
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7 - Upper Charge Air Pipe

tion of the heat shield
mat.
With engine codes
AWP, AWW with a
quick-release connec
tion (with O-ring and re
taining clip).
With engine code AWD
with screw-type clamps.
Prote
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by
6 - from the Air Filter
AG.
5 - to the Crankcase Housing

Ventilation
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From the deceleration
shut-off valve to the up
per charge air pipe.
rrectness of i
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a
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wit
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3 - Pressure Regulator Valve

For crankcase ventila
tion.
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2 - Connecting Hose
To the turbocharger re
circulation valve -N249-
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1 - Deceleration Shut-Off
Valve
Checking, refer to
4.6 Deceleration
Shut-Off Valve, Check
ing, page 166 .

19 - O-ring
Always replace.
20 - Intake Tube
To the intake tube of the turbocharger.
21 - Wastegate Bypass Regulator Valve -N75- */**
Valve is activated (pulsed) by the Engine Control Module (ECM).
Check activation.
2.2
Charge Air Cooler Components Over

view
Note
Various hose connections are secured with clamps.

The charge air system must be properly sealed.
When installing, follow the installation marks on the hoses and
components.
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Note the installed position of the heat shield mats
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155
Prote
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1 - Air Duct
2 - Bolt
10 Nm
3 - Charge Air Pressure Sen
sor -G31 Checking, refer to
4.3 Charge Air Pres
sure Sensor, Checking,
page 163 .
4 - O-ring
Always replace.
5 - Rubber Grommet
With a sleeve.
6 - Bolt
10 Nm
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7 - Intake Tube
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Between theeintake
db
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manifold tand
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cooler.s au
9 - Screw Clamp
engine code AWD.
Vehicles with engine co
des AWP and AWW
with a quick-release
connection (with O-ring
and retaining clip).
11 - Air Guide Pipe
12 - Bracket
AG.
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156
ht
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14 - Charge Air Cooler
rrectne
s
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8 - Heat Shield Mats

tion.

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Exhaust Turbocharger System Overview
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9 - Brake Booster
10 - Non-Return Valve
For the brake booster.
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8 - Wastegate Bypass Regula

tor Valve -N75 Valve is activated
(pulsed) by the Engine
Control Module (ECM).
Check activation.
es, in part or in w
l purpos
hole
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Valve
Prote
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regulator valve.
AG.
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4 - Turbocharger
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rrectness of i
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at
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2 - to the Vacuum Reservoir

Under the right front
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1 - Connecting Hose
From the leak detection
pump -V144- .
b
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2.3
11 - Air filter with Mass Airflow

Sensor -G70- .
12 - Crankcase Housing Ven
tilation Pressure Regulator
Valve
13 - Combination Valve
For the Secondary Air
Injection (AIR) system.
Checking, refer to 4.2 Combination Valve, Checking, page 179 .
16 - Turbocharger Recirculation Valve -N24917 - Secondary Air injection Solenoid Valve -N112 Checking, refer to 4.4 Secondary Air Injection Solenoid Valve, Checking, page 180 .
18 - Crankcase Ventilation
20 - Charge Air Pressure Sensor -G31 Replace the O-ring if damaged.
21 - Secondary Air Injection Pump Motor -V101 Function, checking, refer to 4.3 Secondary Air Injection Pump Motor, Checking, page 179 .
157
AG. Volkswagen A
G do
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Jetta 1999 , Jetta Wagon
ksw1999 , Golf 1998 es not
Vol
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Engine Mechanical e-dEdition
07.2007
ara
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es, in part or in w
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f
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22 - Charge Air
nte
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Coolerss a
rrectness of i
t to the co
nf
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m
spec
atio
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wit
24 - EVAP Canister Purge Regulator Valve 1 -N80 Check activation.

Function, checking, refer to
4.3 Evaporative Emission Canister Purge Regulator Valve, Checking, page 129 .
To the EVAP canister.
2.4
Exhaust Turbocharger System Overview
1 - Connecting Hose
From the leak detection
pump -V144- .
AG.
Prote
cted
by
regulator valve.
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C
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4 - Turbocharger
ht
rig
py
Co
t.
Valve
7 - Brake Booster
For the brake booster.
9 - Wastegate Bypass Regula
tor Valve -N75 Valve is activated
(pulsed) by the Engine
Control Module (ECM).
Check activation.
10 - Air Filter with Mass Airflow
Sensor -G7011 - Crankcase Housing Ven
tilation Pressure Regulator
Valve
For the Secondary Air
Injection (AIR) system.
Checking, refer to 4.2 Combination Valve, Checking, page 179 .
158
thi
sd
o
cu
m
en

Under the right front

15 - Crankcase Ventilation
17 - Turbocharger Recirculation Valve -N24918 - Secondary Air Injection Solenoid Valve -N112 Checking, refer to 4.4 Secondary Air Injection Solenoid Valve, Checking, page 180 .
19 - Suction Jet Pump
21 - Intake Manifold
22 - Charge Air Pressure Sensor -G3123 - Charge Air Cooler
ri
ho
ut
a
ss
tee
or
ac
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rig
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Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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wit
i
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cial p
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mer
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Prote
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by
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.
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To the EVAP canister.
un
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25 - EVAP Canister Purge Regulator Valve 1 -N80 Check activation.

AG. Volkswagen AG d
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Function, checking, refer to
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4.3 Evaporative Emission Canister Purge Regulator
Valve,
Checking,
page
129
.aran
e
s
159

Specifications

Bolt Size
un
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l purpos
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101
301
201
25
30
102
352
Bracket between turbocharger and cylinder block

-
303
10
104
254
Prote
cted
by
c
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py
rig
ht
.
C
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Charge Air Pressure Sensor -G31Air charge cooler
253
404
10
10

2.1.1 Part I, page 151 and see items -13, 14 and 19 For bolt tightening clarification, refer to
2.1.1 Part I, page 151 and see items -26, 27 and 29For bolt tightening clarification, refer to
2.1.1 Part I, page 151 and see items -30 and 32For bolt tightening clarification, refer to
2.1.2 Part II, page 153 and see items -9, 10 and 14-
160
do
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Oil return line

Bracket
or
ac
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
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wit
thi
s
Nut
Coolant supply line
ua
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Exhaust manifold
ss
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40
10
10
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Exhaust pipe nut

Vacuum diaphragm
Intake manifold
Heat shield
Oil supply line
Nm
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Components
ht
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3.1

4.1 Boost Pressure Regulation, Checking, page 161

4.2 Wastegate Bypass Regulator Valve, Checking,
page 163
4.3 Charge Air Pressure Sensor, Checking, page 163
4.4 Turbocharger Recirculation Valve, Checking, page 165
4.5 Boost Pressure Regulator Valve Vacuum Diaphragm,
Checking, page 166
4.6 Deceleration Shut-Off Valve, Checking, page 166
4.7 Charge Air System, Checking for Leaks, page 167
4.1
Boost Pressure Regulation, Checking

Testing and Information System -VAS 5051Test Conditions
by
ed
ris
o
th
au
No leaks on the intake or exhaust sides.
The engine oil temperature is at least 80 C (176 sF).

s
Test Sequence
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There must be no malfunctions stored in the Diagnostic Trou

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Charge pressure is measured under Wide Open Throttle

(WOT) while driving or on a roller type test stand.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
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Observe the safety precautions that apply to road tests. Refer to

engine electronics control module with Address word 01. The
engine must run at idle for this. Connect the fault read out de
vice and select Engine Control Module (ECM).
Scan tool display:

Select function XX

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
AG.
During a road test or on a test stand, check (at full throttle

between 1800 and 2300 RPM) the duty cycle of the wastegate
bypass regulator valve -N75- in display field 4. Specified value:
5.0 to 95.0%

1 2 3 4
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Press buttons 1 1 and 4 for the Display group number 114

and press Q button to confirm input.
ht
rig
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Co
t.
Scan tool display:
If the specified value is not achieved:

Switch to display group 15 as follows: Press 3 button.

1 2 3 4
161

Check the charge air pressure actual value at WOT in display
field 4:
While Driving
with a manual transmission
Accelerate the vehicle at WOT in 2nd gear.
with a automatic transmission
Manually shift the vehicle into 4th gear and accelerate the ve
hicle from low speed at WOT (without kick down, transmission
does not downshift any more).
Engine Codes AWD and AWW
Press print button between 1800 and 2300 RPM and read out
charge air pressure actual value in display field 4. Specified
value: 1350 to 1750 mbar
Engine code AWP
Press print button between 1800 and 2300 RPM and read out
charge air press actual value in display field 4. Specified value:
1700 to 2000 mbar
Compare charge air pressure actual value with specified value
in display field 3. Difference: Max. 100 mbar
Note
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Press key.
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AG. Volkswagen AG d
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Repeat measurement if full charge air pressure
had
not
been
e
nte
is
r
o
reached yet or difference between specified
and
actual
value
is
eo
h
ut
ra
a
too large.
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
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hole
ercia
, is n
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If the boost pressure is exceeded:
Test the charge air pressure sensor -G31- . Refer to
4.3 Charge Air Pressure Sensor, Checking, page 163 .
Check the wastegate bypass regulator valve. (Throughput in
hose from turbocharger via valve to vacuum diaphragm with
connector disconnected)
Check that vacuum diaphragm for charge pressure regulator
valve is securely seated on turbocharger.
r
te o
iva
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Check the wastegate bypass regulator valve.
162
AG.
Test the charge air pressure sensor. Refer to

4.3 Charge Air Pressure Sensor, Checking, page 163 .
agen
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Prote
cted
by c
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C
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If the boost pressure is exceeded:
ht
rig
py
Co
t.
Check the mounting of the boost pressure regulator valve

shaft in the turbocharger for ease of movement. If rusted in
place, replace the turbocharger.
do
c
um
en
Check the vacuum diaphragm. Refer to

4.5 Boost Pressure Regulator Valve Vacuum Diaphragm,

Check the mounting of the boost pressure regulator valve n AG. Volkswagen A
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shaft in the turbocharger for ease of movement. If rusted
kswin
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place, replace the turbocharger.
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an
tee
or
ac
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ris
es, in part or in w
l purpos
hole
ercia
, is n
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t
a
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iv
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f
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The turbocharger is faulty, replace it. Refer to

tho
au
s
2.1 Turbocharger with Attachments Overview,
page 151 .
s
4.2
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

erated.
Wastegate Bypass Regulator Valve,

Checking

Testing and Information System -VAS 5051 B Multi-meter -V.A.G 1526 C-
Connector Test Set -V.A.G 1594 C-
Test Sequence
Disconnect the connector -2- from the wastegate bypass reg

ulator valve -N75- -1-.
AG.
The ignition is turned off.
agen
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C
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Output diagnostic test performed:
ht
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Co
t.
thi
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en
Test Conditions
Prote
cted
by
Measure the resistance between the terminals of the valve.

Specified value: 25 to 35
Replace the wastegate bypass regulator valve.
If the specified value is not achieved:
Check the specified values in measured value blocks for
charge pressure regulation: Display groups 110 to 119.
4.3
Charge Air Pressure Sensor, Checking
163

Multi-meter -V.A.G 1526 A- or -V.A.G 1526 C Connector Test Set -V.A.G 1594 A- or -V.A.G 1594 C Adapter Cable, (121-pin) -V.A.G 1598/31 Wiring Diagram
Test Conditions
A malfunction in the charge air pressure sensor was detected

by On Board Diagnostic (OBD).
es
wage
The ignition is turned off.
Voltage Supply and Wiring to Control Module,
ks
Vol
by
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Checking
au
ss
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
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nl
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n
ility
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an
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ce
Disconnect the 4-pin connector -2- from the charge air pres
sure sensor -G31- (-1-).
not
gu
ara
nte
eo
ra
c
Connect the multi-meter for voltage measurement with adapt

er cables from the connector test set -V.A.G 1594 C- to ter
minals 1 (Ground) and 3 (positive) of the charge air pressure
sensor connector.
Turn the ignition on. Specified value: at least 4.5 V

164
AG.
Check the wires between the adapter cable, (121-pin) -V.A.G

1598/31- and connector for open circuits according to the wir
ing diagram.
agen
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Prote
cted
by c
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p
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gh
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C
op
yi

Engine Control Module (ECM) wiring harness. The ECM re
mains disconnected.
ht
rig
py
Co
t.
If no voltage is present:
do
c
um
en
Turn the ignition off .
Check wires for short circuits to each other.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
If no malfunction is found in the wires and there was voltage be

tween terminals 1 and 3:
Check the function. Refer to page 165 .
If no malfunction is found in the wires and there was no voltage
between terminals 1 and 3:
Replace the ECM. Refer to Fuel Injection and Ignition; Rep.
Gr. 24 ; Removal and Installation .
Checking Function

ECM wiring harness and ECM.
Reconnect the connector to the charge air pressure sensor.
c
o
p
yri
gh
t.
C
op
yi
Start the engine and measure the voltage. Specified value:

1.80 to 2.00 V
ht
rig
py
Co
t.
Use adapter cables from the connector test set -V.A.G 1594
C- to connect the multi-meter to sockets 101 (B+) + 108
(Ground (GND)) for voltage measurement.
do
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es, in part or in w
l purpos
hole
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AG. Volkswagen AG d
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b
ara
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nte
ise
r
o
Jetta
1999
,
Jetta
Wagon
e o 1999 , Golf 1998
h
t
u
ra
a
c
Engine
Mechanical
- Edition 07.2007
s
s
agen
lksw
Vo
by
Increase the engine speed by pressing the gas pedal sudden

ly. Specified value: 2.00 to 3.00 V
AG.
Prote
cted
by

Replace the charge air pressure sensor.
erated.
4.4
Turbocharger Recirculation Valve,

Checking

Multi-meter -V.A.G 1526 C Connector Test Set -V.A.G 1594 C Wiring Diagram
Test Conditions
Output diagnostic test performed.
Test Sequence
Disconnect the connector from the turbocharger recirculation
valve -N249- .
Measure the resistance between terminals of the valve. Speci
fied value: 27 to 30
Replace the turbocharger recirculation valve.
165
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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c
erm
or
e
t
a
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f
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Jetta 1999 , Jetta Wagon 1999 , Golf
ir se 1998
tee
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or
Engine Mechanical - Edition 07.2007au
ac
ss

(ECM) disconnected from the voltage supply, the readiness
code must be regenerated.
Boost Pressure Regulator Valve Vac

uum Diaphragm, Checking
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
4.5

Testing and Information System -VAS 5051 BTest Conditions
The engine oil temperature is at least 60 C (140 F).
No leaks on the intake or exhaust sides.
Test Sequence
Prote
cted
by
If the actuator rod does not move through light prying:

The turbocharger is faulty, replace it. Refer to
2.1 Turbocharger with Attachments Overview, page 151 .
4.6
Deceleration Shut-Off Valve, Checking

Hand Vacuum Pump -V.A.G 1390Test Conditions
Performance deficiency or load change shocks
166
AG.
Check the lever -1- for the boost pressure regulator valve for
ease of movement. If rusted in place, replace the turbocharg
er.
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p
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.
C
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If the actuator rod does not move:
ht
rig
py
Co
t.
Start the engine and increase the engine speed to maximum

RPM by pressing the accelerator pedal suddenly. The actuator
rod -2- for the boost pressure regulator valve must move.
thi
sd
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cu
m
en
Disconnect the connector -2- from the wastegate bypass reg

ulator valve -N75- (-1-).
un
le
pe
rm
itte
d
Test Sequence
Note
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
The deceleration shut-off valve is located in front of the turbo

charger. It is opened by vacuum during deceleration and at idle.
Connect the hand vacuum pump -V.A.G 1390- to the vacuum

connection of the deceleration shut-off valve.
Operate the hand vacuum pump -V.A.G 1390- . The deceler
ation shut-off valve must open in the direction of the -arrow-.
Operate the ventilation valve at the hand vacuum pump -V.A.G

1390- . The deceleration shut-off valve must close
Note
do
c
um
en
r
te o
iva
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rp
fo
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n
If the deceleration shut-off valve does not open or does not close,
replace the valve.
ht
rig
py
Co
t.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Connections of the deceleration shut-off valve are to be fastened

with screw type clamps.
AG.
4.7
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, Jetta Wagon 1999 , Golf 1998

ility
ab
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an
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ce
AG. Volkswagen AG d
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oes
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not
l
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b
ara
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nte 1999
is
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Jetta
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c
s
s
Charge Air System, Checking for Leaks

Testing Unit for Turbocharger -V.A.G 1687 Accessory Adapter -V.A.G 1687/1 Remove the intake hose from the air filter.
Remove the crankcase ventilation pressure regulator valve
from the intake hose.
Insert the accessory adapter -1687/1- into the intake hose and
seal the connection for the pressure regulator valve using the
adapter -V.A.G 1687/4- . Tighten the hose clamps.
Prepare the testing unit for turbocharger -V.A.G 1687- as follows:
Remove the pressure regulator valve -2- completely and close

valves -3 and 4-.
Note
In order to be able to turn the pressure regulator valve -2-, the

rotary knob must be pulled upward.
167

AG. Volkswagen AG d
agen
oes
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not
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ara
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nte
is
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h
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a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
pe
rm
itte
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ility
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un
le
Connect the testing unit for turbocharger -V.A.G 1687- as

shown.
Connect the pressurized air hose -1- (pressurized air supply)

to the testing unit for turbocharger -V.A.G 1687- .
If water is located in the viewing glass, drain it via the water drain
plug -6-.
Prote
cted
by c
o
p
yri
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t.
C
op
yi
Set the pressure to 0.5 bar using the pressure regulator valve
-2-.
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AG.
Caution
Pressure must not exceed 0.5 bar! A pressure set too high may
damage the engine.
Open the valve -4- and wait until the testing circuit has filled.
If necessary, continue to regulate pressure to 0.5 bar.
Check the charge air system for leaking areas by listening,
touch, using leak detection spray or using the ultrasonic meas
uring device -V.A.G 1842- .
Note
A minimal amount of air will escape through the turbocharger
into the oil pan. A retaining pressure test is not possible for this
reason.
Handling instructions of the ultrasonic measuring device -
V.A.G 1842- . Refer to the operating instructions.
If a poorly sealed area is discovered, observe the notes for
charge air system when repairing. Refer to

1.3 Charge Air System with Turbocharger, page 150 .
Before removing the adapter, release pressure from the test
circuit by separating the connection from the accessory adapt

er -1687/1- .
168
ht
rig
py
Co
t.
Open the valve -3-.
do
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Note

Special Tools

Accessory Adapter -V.A.G 1687/1 Adapter Cable, (121-pin) -V.A.G 1598/31 Multi-meter -V.A.G 1526 C- or -V.A.G 1526 A-
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
un
le
es, in part or in w
l purpos
hole
ercia
, is n
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com
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Connector Test Set -V.A.G 1594
es n
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tee
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ac
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s or -V.A.G 1594 AsC-
do
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Hand Vacuum Pump -V.A.G 1390-
agen
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Prote
cted
by
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.
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Testing Unit for Turbocharger -V.A.G 1687-
5. Special Tools
169

26
G do
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ksw Controls
Exhaust System, Emission
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General Information
n AG. Volkswagen A
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tee
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hole
ercia
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erm
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1.1 Secondary Air Injection System Function, page 170
1.1
Caution
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Secondary Air Injection System Func

tion

orative Emission (EVAP) system, coolant, refrigerant,
brake fluid and vacuum) and electrical wiring so that the
original path is followed.
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Rep. Gr.26 - Exhaust System, Emission Controls
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170
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Air is blown behind the exhaust valves by the Secondary Air In

jection (AIR) system for a maximum of 100 seconds following a
cold start (coolant temperature of +5 C to +33 C (+41 F to +91
F)). This produces an oxygen rich exhaust gas, causes after
burning and reduces the heating-up phase of the catalytic con
verter. Activation is triggered by the Motronic engine control mod
ule -J220- via the secondary air injection pump relay -J299- to the
secondary air injection solenoid valve -N112- , (change-over
valve) and combination valve.

2.1 Exhaust System Components Overview, page 171

2.2 Secondary Air Injection System Components Assembly
Overview, page 174
2.1
Exhaust System Components Overview

Note
olkswagen AG
After exhaust system repairs, make sure the exhaustagsystem
en AG. V
do
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is not under stress and that it has sufficient clearance
olks from the
yV
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d
bodywork. If necessary, loosen the doubleisclamps
and clamp
e
r
and align the exhaust pipe so that sufficient
ho clearance is main
t
au carry uniform loads.
tained to the bodywork and support rings
ss
3 - Suspended Mount
tion, refer to
Fig. Installed Loca
tion of the Mount ,
page 173 .
r
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ng
AG.
2 - Center Muffler
As a standard, the cen
ter and rear mufflers are
installed as a single
component. In cases of
repair, the center and
rear muffler are supplied
individually and with a
double clamp for con
necting.
Separating point, refer
to
Fig. Separation
Point on the Exhaust
Pipe , page 173 .
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1 - Tunnel Bridge
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agnostic (OBD).
rrectne
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spec
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Replace self-locking nuts.
es n
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ran
tee
or
ac
4 - Bolt
25 Nm
5 - Nut
40 Nm
Always replace.
6 - Washer
7 - Gasket
Always replace.
8 - Turbocharger
9 - Front Exhaust Pipe with
171

Catalytic Converter
10 - Heated Oxygen Sensor -G39- *
50 Nm
Grease only the threads with hot bolt paste -G 052 112 A3- (anti-seize compound). The hot bolt paste G 052 112 A3- must not get into the slots on the sensor body. (Part numbers are for reference only.
Always check with your Parts Department for the latest part number information).
Use the ring spanner 7-piece set -3337- for removal and installation.
If the sealing ring is leaking cut it off and replace it.
Checking, refer to Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis and Testing .
Connect with engine code AWD: 4-pin, contact gold-plated.
Connect with engine codes AWP and AWW: 6-pin, contact gold-plated.
11 - Oxygen Sensor after Three Way Catalytic Converter -G130- *
50 Nm
Grease only threads with hot bolt paste -G 052 112 A3- (anti-seize compound). The hot bolt paste -G
052 112 A3- must not get into the slots on the sensor body. (Part numbers are for reference only. Always
check with your Parts Department for the latest part number information).
Use the ring spanner 7-piece set -3337- for removal and installation.
If the sealing ring is leaking cut it off and replace it.
Checking, refer to Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis and Testing
Connector: 4-pin, terminals 3 and 4 gold-plated.
12 - Double Clamp
Note the installed position, refer to Fig. Installed Position of the Double Clamp , page 173 .
13 - Nut
40 Nm
14 - Suspended Mount
15 - Bolt
25 Nm
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16 - Rear Muffler
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r
As a standard,
o
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h
t
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centersand
rear muffler are supplied individually and with
a
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Separating point, refer to Fig. Separation Point on the Exhaust Pipe , page 173 .
Installing the muffler free of tension, refer to
Fig. Installing the Muffler Free of Tension , page 173 .
rrectness of i
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spec
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17 - Suspended Mount
18 - Bolt
25 Nm
19 - Double Clamp
20 - Nut
40 Nm
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172
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21 - Bolt
25 Nm
of repair, the

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Separation Point
on the Exhaust Pipe
or
ut
ac
a
ss
Position the repair double clamp -4- between the
-arrows 1 and 3- during installation. Tightening specification
40 Nm
Installing the Muffler Free of Tension

The bolt at the exhaust pipe must be parallel to the tunnel
bridge (dimension -x- same at left and right).
do
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Installed Position of the Double Clamp
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Cut through the exhaust pipe at a right angle at the separating

point -2-.
Position the double clamp approximately 5 mm from the mark

A -arrow 1-.
Note
Mark -A- applies to vehicles with a manual or automatic trans

mission.
Installed Location of the Mount

Angled side at the foot of the suspended mount -arrow- faces
the front of the vehicle.
173

2.2
Secondary Air Injection System Compo

nents Assembly Overview
Note
Components marked with * are checked via On Board Diag
nostic (OBD).
Components marked with ** are checked via output Diagnostic
Test Mode (DTM).
Secondary air injection pump relay -J299- **. Refer to
Fig. AIR Pump Relay -1- , page 175 .
Checking, refer to
4.2 Combination
Valve, Checking,
page 179 .
2 - Gasket
Always replace.
Secured to the cylinder
head.
4 - Bracket
5 - Bolt
10 Nm
6 - Bracket
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8 - Vacuum Hose
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his
9 - Connector
2-pin
10 - Secondary Air Injection

Solenoid Valve -N112- */**
Tightened to 6 Nm on
the bracket.
Resistance: 21 to 24
Checking, refer to
4.4 Secondary Air In
jection Solenoid Valve,
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13 - O-ring
Always replace.
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12 - to the Air Filter
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11 - Intake Tube
For the Secondary Air Injection (AIR) pump.
Ensure it is seated tightly.
Squeeze together at the front to release.

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15 - Nut
10 Nm
un
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14 - Connector
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For the AIR pump motor.sed b
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18 - Pressure Hose
Ensure it is seated tightly.
Squeeze together at the front to release.
19 - Nut
10 Nm
Secured to the bracket -item 6-.
20 - Bolt
10 Nm
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AIR Pump Relay -1-
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21 - Gasket
Always replace.
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17 - Bolt
10 Nm
If tools are necessary to pull the relay or control module out of

the relay plate, first disconnect the battery Ground (GND) ca
ble.
AG.
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by
Obtain the radio code for radios with a anti-theft code before
disconnecting the battery.
175
wagen AG
. Volks
Jetta 1999 , Jetta Wagon 1999 w,aGolf
1998
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-
25
40
50
40
25
25
10
10
10
Suspended mount
Front exhaust pipe with catalytic converter
Oxygen Sensor
Double clamp
Suspended mount
Tunnel bridge
Bracket for connecting piece secured to
cylinder head
Secondary Air Injection Solenoid Valve N112- on bracket
Secondary Air Injection Pump Motor V101Pressure hose
Prote
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176
AG.
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Components
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wit
3.1
or
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Specificationsss
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4.1 Three Way Catalytic Converter, Checking, page 177

4.2 Combination Valve, Checking, page 179
4.3 Secondary Air Injection Pump Motor, Checking,
page 179
4.4 Secondary Air Injection Solenoid Valve, Checking,
page 180
4.1
Three Way Catalytic Converter, Check

ing

Testing and Information System -VAS 5051 B Speed Adjuster Tool -V.A.G 1788/10- (only on engine codes
AWD and AWW)
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Connect the fault read out device
-V.A.G
1551and
select
the
nte
is
r
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eo
h
engine electronics control module
with Address word 01. The
ut
ra
a
c
engine must run at idle for
this.
Connect
the
fault
read
out
de
s
s
Test Sequence
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vice and select the Engine Control Module (ECM).

Scan tool display:

Select function XX
Scan tool display:
Initiate basic setting HELP

Press buttons 0 3 and 4 for the Display group number 34

and press Q button to confirm input.

1 2 3 4

Adjust the engine speed using the speed adjuster tool -V.A.G
1788/10- to 1800 to 2200 RPM:
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Continue to hold the speed at 1800 to 2200 RPM until the

specified value B1S1 OK is shown in display field 4.
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field 4 goes from Test OFF to Test ON. Catalytic converter
temperature in display field 2 must be between 350 and 500
C (662 and 932 F).
AG.
Engine Code AWP
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form
spec
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Press buttons 0 and 4 for function Initiate basic setting and


Press the gas pedal to the Wide Open Throttle (WOT) position.
The engine speed is raised to approximately 2300 RPM by the
ECM.
Hold the brake and gas pedal down until the display in display
temperature in display field 2 must be between 350 and 500
C (662 and 932 F).
Continue to hold the brake and gas pedal until the specified
value B1S1 OK is shown in display field 4.
177

If the reading does not result as described:
erated.
Read the results as described:
Press C key.
Basic setting 46 ->

1 2 3 4

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temperature in display field 2 must be at least 440 C e(824
ara
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F).
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Remove the speed adjuster tool -V.A.G 1788/10- from the gas
pedal.
Engine Code AWP
or
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s
Continue to hold the speed at 1800 to 2200 RPMsuntil
specified
value Catalytic convert B1 OK is shown in display field 4.
Press the gas pedal to the WOT position. The engine speed
is raised to approximately 2300 RPM by the ECM.
Hold the brake and gas pedals down until the display in display
temperature in display field 2 must be at least 440C (824 F).
Continue to hold the brake and gas pedals until the specified
value Catalytic converter B1 OK is shown in display field 4.
Catalytic converter B1 not OKB shown in display field 4:
AG.

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If the specified value Catalytic converter B1 OK:

Press key.
Scan tool display:
178

Select function XX
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4.2
Combination Valve, Checking

Hand Vacuum Pump -V.A.G 1390Test Conditions

ble Code (DTC) memory
Output diagnostic test performed
agen
Vacuum lines and hose connections are free of leaks
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Vacuum lines are not blocked or
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Test Sequence
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Disconnect the vacuum hose -1- from the secondary air injec
tion solenoid valve -N112- -2-.
Note
rrectness of i
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nf
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m
spec
atio
h re
n in
wit
Connect the hand vacuum pump -V.A.G 1390- to the vacuum

hose -1-.
Do not use compressed air during the following check!
Disconnect the pressure hose -3- from the secondary air in

jection pump motor -V101- and blow air in with light pressure
-arrow-. The combination valve must be closed.
AG.
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If the combination valve does not open:
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Operate the hand vacuum pump -V.A.G 1390- . The valve

must open.
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To disengage, squeeze the buttons at the hose coupling.
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Note
Replace the combination valve.
4.3
Secondary Air Injection Pump Motor,

Checking

Testing and Information System -VAS 5051 B-
179

Test Conditions
The secondary air injection pump relay -J299- fuse -arrow- in

the main fuse box is OK.

The Secondary Air Injection (AIR) intake hose is not sealed or

kinked.
Test Sequence
rrectness of i
t to the co
nform
spec
at
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h re
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es, in part or in w
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Note
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Install the pressure hose to the secondary air injection

motor -V101- .
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pump
s
To disengage, squeeze the buttons at the hose coupling.
Activate the AIR pump relay via the output Diagnostic Test
Mode (DTM).
The AIR pump motor must start in intervals and air must es
cape at the exhaust connection.
If the motor starts, but no air escapes:
Continue with the output DTM to the end.

If the AIR pump motor does not start up in intervals:

Check the AIR pump motor activation.
4.4
Secondary Air Injection Solenoid Valve,

Checking
Test Conditions
Coolant temperature is 5 to 33 C (41 to 91 F).
The Secondary Air Injection (AIR) pump motor is OK.

180
AG.

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Replace the AIR pump motor.
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t.

Test Sequence
Disconnect the vacuum hose -arrow- from the at combination
valve.
Start the engine and let run at idle. Vacuum must be present
at the vacuum hose (sense by touch) when the secondary air
injection pump motor -V101- is running.
If no vacuum can be felt:
Turn off the engine.
Check the valve activation. Refer to Fuel Injection and Ig
nition; Rep. Gr. 01 ; Diagnosis and Testing .
rrectness of i
t to the co
nf
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r
m
spec
atio
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n in
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Special Tools

Testing and Information System -VAS 5051 B Speed Adjuster Tool -V.A.G 1788/10-
es, in part or in w
l purpos
hole
ercia
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AG. Volkswagen AG d
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Hand Vacuum Pump -V.A.G 1390-
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Edition 06.28.2012 FB
AG. Volkswagen AG d
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Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
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If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
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Page 1 of 3
2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings

=
Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
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grinding, sanding, or byagcleaning
air. Avoid breathing asbestos fibers and asbestos dust.
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Breathing asbestos
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shorts, get caught in running machinery, or be
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Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
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Page 2 of 3
Version 1.0
Cautions & Warnings

=
Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
agen AG of ignition away from the tire repair
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inflated using an aerosol tire inflator. Keep sparks, open flame
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not rim. Completely remove the
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area. Inflate and deflate the tire at least four times before
breaking
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tire from the rim before attempting any repair. rise
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I have read and I understand these Cautions and Warnings.
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never hold test equipment in your hands or lap while the

vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
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Page 3 of 3
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Service

AWD AWW AWP

Service Department. Technical Information

26 - Exhaust System, Emission Controls

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

Cylinder Head Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

Secondary Air Injection System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

General, Technical Data

1.1 Engine Number, page 1

The engine number (engine code and serial number) are lo

In addition, a sticker with the engine code and serial number

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

2.1 Engine Data, page 2

TLEV = Transitional Low Emission Vehicles (emission val

Rep. Gr.00 - General, Technical Data

Knock sensor control

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

1.1 Engine and Transmission Mounts, Aligning, page 3

Engine and Transmission Mounts,

-b- = minimum 10.0 mm

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

The Air Conditioning (A/C) refrigerant circuit must not be

trained personnel and the necessary range of tools and work

To prevent damage to the A/C condenser and also to the re

To facilitate removal and installation of the engine without having

Remove the A/C compressor. Refer to Heating, Ventilation

Shield the bumper from damage using adhesive tape.

Rep. Gr.10 - Engine Assembly

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

2.1 Engine Mount Tightening Specifications, page 5

Engine Mount Tightening Specifications

Pendulum support to subframe 1

Fastener Tightening Specifications

Bolts and Nuts

Pendulum support to transmission 40 Nm + an addition

Pendulum support to transmission 40 Nm + an addition

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

Rep. Gr.10 - Engine Assembly

Jetta 1999 , Jetta Wagon 1999 , Golf 1998

Removal and Installation

3.1 Engine, Removal, page 7

Special tools and workshop equipment required

Shop Crane -V.A.G 1202- or Shop Crane -VAS 6100-

Grease -G 000 100- (vehicles with a manual transmission)

First, check whether a coded radio is installed. If necessary,

The engine is removed downward together with transmission.

Disconnect the battery Ground (GND) cable with the ignition

3. Removal and Installation

Squeeze the buttons together on the hose connections to remove

The fuel supply line is under pressure! Wear protective goggles

Rep. Gr.10 - Engine Assembly

Remove the connecting hoses -arrows- between the Secon